Chassis for pneumatic vehicle

ABSTRACT

A pneumatic vehicle is provided with an elongate compressed air tank, a chassis assembled with the tank oriented longitudinally in the chassis where the tank is a load-bearing structural chassis member, wheels connected to the chassis, and a powertrain driven by the compressed air and operably connected to one of the wheels. A chassis for a pneumatic vehicle is provided with an elongate compressed air tank, a first series of side support members connected laterally to the air tank, a second series of side support members connected laterally to the air tank, a first side panel connected to the first series of side support members, a second side panel connected to the second series of side support members, wheels connected to the side panels, and a powertrain driven by the air in the compressed air tank and connected to one of the wheels.

BACKGROUND

1. Field of the Invention

Embodiments of the invention relate to chassis for pneumatic vehicles.

2. Background Art

Henry Ford's Model T Mission Statement: “I will build a car for thegreat multitude. It will be large enough for the family, but smallenough for the individual to run and care for. It will be constructed ofthe best materials, by the best men to be hired, after the simplestdesigns that modern engineering can devise. But it will be low in pricethat no man making a good salary will be unable to own one- and enjoywith his family the blessing of hours of pleasure in God's great openspaces.”

According to an Australian government report, a life cycle assessment(LCA) “Is a tool for assessing the environmental impacts associated witha product, process or service throughout its life cycle, from theextraction of raw materials through to the processing, transport, use,reuse, recycling and disposal.” LCA is commonly known as cradle to graveas it is from the birth of the product right through to its final stage.

There are a number of benefits that can be realized from completing alife cycle assessment (LCA) on a product. According to the Australiangovernment some of these benefits include:

-   -   identifying the most efficient options for increasing the        environmental performance of a product, and creating a “greener”        product that is more desirable to customers;    -   identifying places in the company where efficiency improvements        can be made;    -   reducing greenhouse emissions;    -   comparing alternative choices;    -   identifying the most relevant steps in the manufacturing process        related to a given environmental impact;    -   providing a tool for decision making.

However, LCA is a “new technology” and hence there are some challengesin conducting an LCA. Some of these challenges include (AustralianGovernment):

-   -   Lack of a widely accepted methodology for conducting LCA;    -   Difficulties of defining the scope and boundaries of the LCA;    -   Confidentiality issues that restrict the availability of        relevant data;    -   Time taken to complete a full LCA.

There are four stages/steps to conducting an LCA as defined by the ISO14040 standards, these steps are:

1. Goal and Scope Analysis: These are the specifications of the LCAstudy; it suggests what questions are going to be answered andidentifies who the study is for. It also defines the purpose, barriersand limitations of the study. The final part of the scope defines thedata required to fulfil the requirements.

2. Inventory Analysis (IA): The inventory analysis is the step wheredata is gathered, and data from each material and process are qualifiedand validated. This step can be very difficult because of concerns overrevealing proprietary and/or confidential information.

3. Life Cycle Impact Analysis: According to the ISO 14044 impactanalysis is the phase of life cycle analysis aimed at understanding andevaluating the magnitude and significance of the potential environmentalimpacts for a product system throughout the life of the product.

4. Improvement Analysis: An objective of this phase is to improve theenvironmental performance of the project or process in question. That isto compare all the data and results to see how they can be used to makeimprovements in the product or manufacturing.

SUMMARY

An embodiment of a pneumatic-powered automotive vehicle has an elongatetank for storing compressed air, a chassis assembled with the tank suchthat the tank is oriented longitudinally in the chassis and provides aload-bearing structural member in the chassis, a plurality of wheelsconnected to the chassis, and a powertrain in fluid communication withthe tank for being driven by the compressed air and operably connectedto one of the wheels.

An embodiment of a chassis for a pneumatic-powered automotive vehiclehas an elongate tank for storing compressed air, a first series of sidesupport members connected to the air tank and extending laterallyoutboard from a first lateral side of the air tank, and a second seriesof side support members connected to the air tank and extendinglaterally outboard from a second lateral side of the air tank oppositeof the first lateral side. The chassis also has a first side panelconnected to the first series of side support members, a second sidepanel connected to the second series of side support members, aplurality of wheels connected to the side panels, and a powertrain influid communication with the tank for being driven by the compressed airand operably connected to one of the wheels for driving the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overhead view of a city showing heavy traffic in theemerging metropolises;

FIG. 2 is a table of Vehicle Attribute Ranking;

FIG. 3 is a table of System decomposition metrics;

FIG. 4 is a Consumer needs-metrics matrix;

FIGS. 5 a and 5 b are a table of Benchmarked competitors' vehiclespecifications and the pneumatic vehicle;

FIG. 6 is a table of Vehicle Level Design Targets;

FIG. 7A is a side elevation view of a pneumatic vehicle according to anembodiment;

FIG. 7B is a top plan view of the pneumatic vehicle;

FIG. 8 is a perspective view of powertrain components of the pneumaticvehicle and their packaging location;

FIG. 9 is a graph illustrating the calculated Power & Torquerequirements for the vehicle as a function of vehicle speed;

FIG. 10 is a selection process diagram with both the engine selectioncriteria and engine possibilities;

FIG. 11 is a table of Weight saving by eliminating the need for somecommon powertrain components;

FIG. 12 is front view of a natural gas home filling station(http://www.myphill.com/index.htm);

FIG. 13 is a Comparison table showing electricity cost and fill timesfrom 9 different size compressors; all compressor figures and modelstaken from (http://www.bauer-kompressoren.de/en/index.php); electricitycost is the Michigan State average as of March 2007;

FIG. 14 is perspective view of the compressed air tank of the pneumaticvehicle and its materials;

FIG. 15 is a side view of an aluminum scuba tank after explosion(http://www.thesailingsharkadventures.com/html/cylinder_fills_and_safety.html);

FIG. 16 is a table of Fossil fuel emission levels—pounds per billion Btuof energy input, taken from(http://www.naturalgas.org/environment/naturalgas.asp);

FIG. 17 is a flow diagram illustrating thermodynamic processes forcompressed air vehicle propulsion, following a similar model to:Thermodynamic Analysis of Compressed Air Vehicle Propulsion, Ulf Bossel,European Fuel Cell Forum;

FIG. 18 is a perspective view of a rotary air motor;

FIG. 19 is an exploded perspective view of a burner assembly for thepneumatic vehicle;

FIG. 20 is a perspective view of the burner assembly with the housing;

FIG. 21 is a side view of a counterflow heat exchanger design;

FIG. 22 is a plan view of a heating, ventilating and air-conditioning(HVAC) layout and integration with the counterflow heat exchanger;

FIG. 23 is another plan view of the HVAC system and integration with thecounterflow heat exchanger;

FIG. 24 is a perspective view of the HVAC system and integration withthe counterflow heat exchanger;

FIG. 25 is a side sectional view (25 a) and a perspective view (25 b) ofthe pneumatic vehicle illustrating the placement of the powertrainwithin the vehicle;

FIG. 26 is a top view and side view of the pneumatic vehicleillustrating vehicle dimensions and a center of gravity;

FIG. 27 is a top view of a vehicle chassis illustrating rolloverkinematics and threshold for the pneumatic vehicle;

FIG. 28 is a table of a Comparison of Rollover threshold for thepneumatic vehicle and other typical vehicle types (www.rqriley.com);

FIG. 29 is a top view of the pneumatic vehicle illustrating thecapabilities of differential steering combined with a trailing rearwheel to allow the pneumatic vehicle to virtually ‘turn on the spot’;

FIG. 30 is a side view of the rear wheel suspension geometry indicatingan appropriate rear trail;

FIG. 31 is perspective views of a 1/10th scale remote control prototypedeveloped to validate and tune the pneumatic vehicle's steering system;

FIG. 32 is a series of top views of the automation of a rotary steeringdamper, controlling the wheels sweep angle and damping co-efficient asthe pneumatic vehicle speeds change;

FIG. 33 a and FIG. 33 b are perspective views of a symmetrical doublewishbone suspension system integrating the rotary air motors as theupright;

FIG. 34 is an exploded perspective view of a front outboard suspensionassembly illustrating the direct drive hub motor;

FIG. 35 is an exploded perspective view of a stamped AHSS lower wishboneand a cast alloy upper wishbone;

FIG. 36 is from left to right, an exploded perspective view of the rearsuspension and wheel, a perspective view of the rear suspension assemblyon the pneumatic vehicle, and a fragmentary perspective view of a rearsuspension assembly;

FIG. 37 a perspective view illustrating an electro-hydraulic brakingsystem, having a single piston floating caliper activated by anelectronic linear actuator;

FIG. 38 is a schematic view of a Double Circuit Master Cylinder;

FIG. 39 is a Parts list for the Front Suspension Assembly;

FIG. 40 is a Parts list for the Rear Suspension Assembly;

FIG. 41 is a perspective view of a lower vehicle body assembly (left)and a perspective view of an upper vehicle body assembly (right);

FIG. 42 is an exploded perspective view of the lower pneumatic vehiclestructure;

FIG. 43 is a Parts List for the Lower vehicle structure;

FIG. 44 is a perspective view of the lower pneumatic vehicle structureand the materials and manufacturing processes used therefore;

FIG. 45 is a top view of examples of part shapes achievable using aflexible roll forming process (a) and a perspective view an example ofthe machinery and tooling required for the roll forming process (b)(www.ortic.se);

FIG. 46 is a fragmentary perspective view of an air tank attachmentsystem for the pneumatic vehicle;

FIG. 47 is a graph illustrating specific energy absorption (SEA) valuesfor typical crash tube materials;

FIG. 48 is a series of side view photographs illustrating a dynamicaxial crush test of carbon-fiber reinforced plastic (CFRP) tubes;

FIG. 49 is a perspective view of a simplified offset frontal crashfinite element analysis (FEA) load case, used for the design of thefront structure of the pneumatic vehicle;

FIG. 50 is top view illustrating load paths into the lower (left) andupper (right) pneumatic vehicle structures for an offset frontal impact;

FIG. 51 is a perspective image of (a) method of CFRP tube manufacture,and a graph illustrating (b) comparison of cure cycle times forcomposite layering vs. autoclave processes;

FIG. 52 is a side sectional view and a perspective view of the pneumaticvehicle lower assembly illustrating the load paths for a side impact;

FIG. 53 is an exploded perspective view of the upper vehicle body;

FIG. 54 is a perspective view of the upper vehicle body illustratingmaterials and manufacturing processes used;

FIG. 55 is a perspective view of a resin transfer molding (RTM) processfor thermosets;

FIG. 56 is a side view and a perspective view illustrating load paths inthe vehicle structure;

FIG. 57 is pie charts illustrating a summary of materials andmanufacturing processes used in the pneumatic vehicle;

FIG. 58 is a Parts List for the Upper vehicle body;

FIGS. 59 a-c are side perspective views of an interior of the pneumaticvehicle;

FIG. 60 is a side sectional view of the pneumatic vehicle interior;

FIG. 61 is perspective view of a seat design illustrating anincorporated inflatable silicon bladder to provide support for a diverserange of passengers;

FIG. 62 is perspective views of a rear bench seat that allows seatingfor a single adult (deflated central section, left) or for two children(inflated central support, right);

FIG. 63 is a perspective view of front vehicle seats illustrating how afront passenger seat can fold horizontally flat, allowing a greatingress/egress and storing space;

FIG. 64 is a perspective view of a removable interior floor lining;

FIG. 65 is a functional diagram of the drive-by-wire using a LocalInterconnect (LIN) protocol;

FIG. 66 is a graph illustrating the LIN system compared to currentconventional communication systems in pneumatic vehicles in terms ofdata rate;

FIG. 67 is a schematic view illustrating the positioning of controlunits throughout the car, and their connectivity to a Car Control Unit(CCU);

FIG. 68 is a schematic view illustrating an Instrument Cluster andMedia-Climate Control Unit (ICMCCU) connection hierarchy;

FIG. 69 is a connection diagram for a drive train control unit (DTU);

FIG. 70 is a schematic illustrating power generation and flow;

FIG. 71 is a schematic view of systems of the pneumatic vehicle thatutilize manufacturing systems to reduce costs and vehicle weight;

FIG. 72 is a perspective exploded view of a front suspension system;

FIG. 73 is a perspective exploded view of a wheel and tire;

FIG. 74 is a schematic view illustrating the parts in a RTM versus aconventional body;

FIG. 75 is a schematic view illustrating the RTM process;

FIG. 76 is a table of Parts manufactured using the RTM process;

FIG. 77 is a schematic view of the composite layer process;

FIG. 78 is a schematic illustrating the bending forming process in rollforming;

FIG. 79 is a table of Parts manufactured using the Roll Forming Process;

FIG. 80 is a table of Parts manufactured using a Stamping process;

FIG. 81 is a table of Parts manufactured using the Casting Process;

FIG. 82 is a table of Parts manufactured by the Injection MoldingProcess;

FIG. 83 is a pie chart illustrating parts purchased and manufacturedwith various processes;

FIG. 84 is schematic view of an assembly, service and sales facility;

FIG. 85 is a perspective view and a top view of a model of a home withthe pneumatic vehicle and a compressor;

FIG. 86 is a table of Estimates of energy and wastes produced by variousraw materials (Source: Sullivan (2001)—Life Cycle Assessment);

FIG. 87 is a Life Cycle Investment (LCI) of a modern generic vehicle(Source: Sullivan (2001)—Life Cycle Assessment); and

FIG. 88 is a LCI of the pneumatic vehicle.

DETAILED DESCRIPTION OF EMBODIMENTS

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention that may be embodied in variousand alternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for the claims and/or as a representative basis forteaching one skilled in the art to variously employ the presentinvention.

A vehicle concept was developed that would satisfy the wants and needsof the target market, as well as provide an environmental sustainablecar that would respond to the global challenges of climate change.

Our design philosophy was influenced by Henry Ford's original thinking,which was new and different, and embraced simplicity and functionalityin design. Henry Ford integrated his knowledge of materials, design andmanufacturing to: combine functions of components into single systems;simplify the manufacturing of components and assemblies; and introduceadvanced materials to the design. Our philosophy was also extended toadopt a holistic approach to not only the concept vehicle's design anddevelopment, but also the urban context in which it operates.

At least one embodiment is a small 3 wheel car, where the two frontwheels are driven by hub mounted motors. The wheel hub motors are drivenby compressed air supplied from a 60 liter carbon fiber storage tank andcomplemented when required by compressed natural gas supplied from a 2.2liter storage tank. The chassis consists of roll formed ultra highstrength steel, several stamped parts, and reinforced polymer upperstructures to minimize weight and manufacturing costs.

Factors of our innovative and revolutionary design include:

-   -   The use of high torque compressed air wheel hub motors to reduce        vehicle emissions to zero, depending on the distance option        chosen;    -   The use of the high torque wheel hub motors enables the        elimination of the conventional powertrain consisting of a        reciprocating internal combustion engine including numerous        auxiliary drives, gear box, clutch, copious universal joints, a        driveline or transaxles. This represents a significant saving in        cost and weight and a reduction in the overall carbon foot print        involved in the vehicle's manufacture and over its life cycle.    -   Differential wheel speeds are used to steer the vehicle via the        wheel hub motors which eliminates the need for a conventional        rack-and-pinion steering system. This simplifies the steering        and suspension system, not to mention weight saving, and the        significant savings in the overall cost of the vehicle;    -   The unique low cost, highly efficient powertrain only uses        energy on demand, so that when the vehicle is being driven        compressed air is drawn from the storage tank to suit the        demands of the operating environment. However, when the vehicle        is stationary, for example at traffic lights or is caught in a        traffic jam, then no compressed air is drawn from the storage        tank.    -   Utilizing the wheel hub motors and the trailing rear wheel        increases the agility and maneuverability of the vehicle in        especially in city and urban contexts;    -   The use of Ultra High Strength Steels in the vehicle chassis and        the application of novel manufacturing methods to increase        strength that reduces the overall weight and cost;    -   The carbon emissions created from our vehicle are concentrated        at the power generation side through the air compressor filling        stations. It is our belief that greater efficiencies can be        found through large economies of scale of renewable power        generation than implementing small scale renewable power        generation on each car. For example, solar cells can only run at        maximum efficiency if they are always facing the sun (or solar        concentrator), which is not always possible on a vehicle;    -   A flexible vehicle design with an easily adaptable human-machine        interface that will keep the vehicle competitive for at least a        decade of advances in software technology;    -   The simplicity of the design and assembly means that alternative        assembly strategies can be adopted including the assembly of the        vehicle at Dealers, which was the original business model used        by Ford Australia back in the early 1900's when the Model-T was        first marketed and sold in Australia and New Zealand.

INTRODUCTION

This section provides an overview of the initial design approach and theformulation of our design philosophy-Integrated Simplicity. It outlinesthe proposed mission statement, our market and consumer selectionapproach and the development of system level needs and metrics requiredto ensure the design of embodiments of the invention was successful.

Oct. 1, 2008 is the 100 year anniversary of the launch of the Model-TFord. This revolutionary car dominated the automotive industry for thenext two decades.

In the Asia/Pacific region there is more than half of the world'spopulation (over 3 billion people). This enormous population is justbeginning to enjoy a rising standard of living, greater economic freedomand increasing purchasing power. The Asia/Pacific region is where futurenon-traditional consumers will be found, and typically this will be inthe growing metropolises of China and India. For example, Shanghai hasover 18 million people, some estimate total population at 25 million,and growing.

Some factors for inclusion in our design included: city driving,flexibility in use, agility, space saving, need for low emissions, easyto park. If embodiments of the invention are to dominate in the 21stCentury like the Model-T did in the previous century, then our conceptcontemplates upgrades both in hardware and software.

Our design objectives were therefore to provide:

-   -   A cost effective design;    -   An innovative design;    -   High quality passenger protection;    -   A robust lightweight vehicle;    -   A step change in the manufacturing and assembly of the vehicle;    -   A reduction in the environmental impact consistent with global        consumer concerns;    -   Consumer appeal to satisfy a wide and diverse market.

Consumer Needs, Concept Metrics, and Design Targets

Mission statement for Embodiments of the present invention: “We aim todeliver a concept for a vehicle which will revolutionize the wayautomobiles are manufactured, used and perceived. It should push theboundaries of current automotive thinking, leading the way in vehicleand manufacturing innovations. It should be affordable for all to ownand maintain, suiting a great multitude of people from diversebackgrounds. It should be sustainable and environmentally friendly, withits existence prevailing well into the future. This project will involveskills, expertise and knowledge from a broad range of disciplines.”

The mission for our vehicle design was to create a revolutionary,simple, practical, and innovatively sustainable vehicle. To completethis mission the consumer needs have to be identified to ensure thevehicle is both a revolutionary car and a popular car.

Consumer Needs

The target market for the concept car is the growing cities of China andIndia. See FIG. 1. Our market research from surveys and interviews withcity drivers in India (Bangalore and Chemai) provided the followinganecdotal advice:

-   -   Highly populated cities in south Asia have an average driving        speed of 16 kmph and therefore it is pointless to buy expensive        cars which claim to go 0 to 60 kmph in 5 seconds;    -   Increasing rates of fuel in south Asian countries are a big        concern for drivers;    -   Instead of purchasing a second hand car customers may like to        buy a no frills, functional brand new car.

The persons interviewed ranged from university students and youngprofessionals to family bread winners and home makers. Similar advicewas received from colleagues and associates who had grown up in China.We then developed consumer needs from our survey data and our intuitionabout what the non-traditional consumer may want.

We have targeted the large busy city user within the Asian/Indianregion. We believe that there is scope to cross over to the crowdedcities of Europe, if the correct quality vehicle can be produced. Ouridentified consumer needs were as follows:

-   -   Cheap to purchase;    -   Cheap to run/maintain;    -   Ease of parking, maneuverability in busy cities;    -   Versatility;    -   Relative storage capacity;    -   Stylish design;    -   Good performance;    -   Safe.

Technology Push

We believe that new technologies and innovative ideas can be pushed onto the market via the vehicle concept:

-   -   New efficient and effective manufacturing ideas;    -   New material selection;    -   Vertical integration-assembly process;    -   Innovative mechanical/vehicle design;    -   Innovative powertrain choice;

Vehicle Attribute Definition

The classification of vehicle attributes was developed according to theconsumer needs and manufacturer descriptors. See FIG. 2.

Concept Metrics

Once the consumer needs are determined, measures or metrics aredetermined so that the developed concepts can be assessed or rankedagainst each other and against other competitors.

The system metrics were determined and are shown in FIG. 3. Theneeds-metrics matrix shown in FIG. 4 ensures all of the consumer needsare covered by the determined metrics.

A benchmarking exercise was undertaken to determine how the competitors'cars compare against the metrics. The compared cars were: Smartcar—2008, Tata Nano, Hyundai i10—2008, Toyota Yaris—2008, ToyotaIQ—2009, Mitsubishi—2005, Chevrolet Spark, Chery QQ3, Maruti 800 Duo,Daihatsu Trevis. The comparison of the benchmarked vehiclespecifications is shown in FIGS. 5 a and 5 b with the final vehiclespecification shown for the vehicle concept car detailed in the firstcolumn.

Design Targets

After reviewing the benchmarking results and determining thebest-in-class vehicles, design targets shown in FIG. 6 were created suchthat our concept would be a competitive car.

Vehicle Design

A pneumatic vehicle 100 is illustrated in FIGS. 7A and 7B according toan embodiment of the invention. This section reviews the engineeringbehind the pneumatic vehicle design. The engineering analysis and thedetail behind the decisions are discussed. The section begins with asection on a powertrain, which outlines the reasoning behind choosing acompressed air motor, as well as the benefits of using a hub motor. Thepneumatic vehicle dynamics section defines the stability of thepneumatic vehicle design. Front and rear suspensions are also reviewedand are followed by the section on the pneumatic vehicle's structure.The structure is defined and the details of some of the manufacturingsystems are described. This is followed by sections describing theinterior of the car, and the control systems within the pneumaticvehicle 100.

Powertrain

The pneumatic vehicle powertrain 102 is an innovative integrated designthat simplifies mainstream current vehicle powertrain designs. Thisbrings many benefits to the pneumatic vehicle 100, namely:

-   -   Excellent integration of components;    -   Simplicity;    -   Greatly lowered part count;    -   Reduced area needed for powertrain components;    -   Reduced maintenance requirements over conventional powertrain        options.

Selection of powertrain alternatives was completed with severalcriteria. As with the rest of the car the design criteria includedefficiency, integration, simplicity, cost and weight. Current vehiclepowertrain solutions are inefficient, heavy and complex. Components likegearboxes, differentials and reciprocating engines all have significantparasitic and rotational losses that greatly reduce the overallefficiency of the vehicle.

The pneumatic vehicle 100 incorporates two hub motors 104 powered byheated air. This means that complex and expensive components like thegearbox, differentials and drive shafts are no longer required. The fuelstorage 106, in this case air, is located down the center of the car 100and forms a backbone to the chassis and body structure.

In order to get greater efficiency/range out of the air stored in theair cylinder 106, the air can be heated. This is done by passing the airthrough a heat exchanger 108 heated by a small natural gas burner 110.The burner 110 and heat exchanger 108 are located in the front of thepneumatic vehicle 100 whereas a Compressed Natural Gas (CNG) cylinder112 is located at the rear of the pneumatic vehicle 100. FIG. 8 showsthe powertrain 102 solution for the pneumatic vehicle 100 concept.

Powertrain Targets

The powertrain 102 related targets set for the vehicle 100 concept areas follows:

-   -   Excellent Parking/Maneuverability;    -   Safe;    -   Environmentally Friendly;    -   Low Cost (both manufacture and purchase);    -   Ease of Manufacture;    -   Cheap to Run/Maintain;    -   System Integration;    -   Simplicity;    -   Vehicle top speed—110 km/h (68 mph);    -   Vehicle acceleration—0-100 km/h (0-62 mph) in less than 16        seconds;    -   Range—200 km.

These targets were used to evaluate the feasibility of 4 powertrainoptions, as shown in the following section.

FIG. 9 shows the calculated torque and power requirements. These figureswere calculated using an acceleration of 0-100 km/h of 16 seconds andtake into account rolling and aerodynamic resistances.

Engine Concept Selection Criteria

The selection process was guided by a prioritized set of criteria; thisis depicted in FIG. 10. The connections on the left show possiblealternatives whilst the connections on the right and center show thecriteria used to narrow down possible alternatives.

The power source for the car 100 should be environmentally friendly bothin its manufacture and in its use by the end user. In addition, thepowertrain 102 system should be environmentally friendly at the end ofits lifecycle (when it is disassembled).

With today's level of uncertainty about the life of oil based fossilfuels and global warming, it was evident that the pneumatic vehicle 100should distance itself from inefficient reciprocating engines using oilbased derivatives as a fuel source.

From the design criteria it was decided that the pneumatic vehicle 100would incorporate hub motors 104 into the front wheels 114. More detailson the maneuverability of a pneumatic vehicle 100 with hub motors 104can be found in the Vehicle Dynamics section. Using a hub motor 104enables significant gains in manufacturing costs, weight and packaging.FIG. 11 shows the possible weight benefits that can come from placingthe motors 104 in the hub of the wheels 114. This initiative gave theoptimum compromise of the above selection criteria. As for packaging,using a hub motor approach allows for greater flexibility and freedom toplace components and systems in unobtrusive places. This means the wholepowertrain 102 system can be unobtrusive to both the passenger andstorage compartments. The two possibilities for hub motors 104 areeither electric or pneumatic.

Comparison of Electric and Pneumatic Hub Motors

The package space for either electric or pneumatic motors 104 will besimilar. Both types of engines are of a similar size. The performance ofboth engines is similar with regard to torque and power curves, withapproximately similar efficiencies. The weight of an air engine 104 maybe marginally higher than an electric engine due to the high pressuresthat the engine runs at. Both engines will have zero carbon emissionsfrom the vehicle side (however, both would need some form of recharging,generally this is provided by the grid).

One of the challenges with compressed air hub motors 104 can be thepowering the auxiliaries. The common engine auxiliaries (power steering,air conditioning condenser & alternator) can all be replaced byalternate systems to give the same result. The pneumatic vehicle 100design actually does away with the need for both power steering and anair conditioning condenser. Power steering is inherent due to the designof the pneumatic vehicle 100, which uses the speed difference betweenthe front wheels 114 to turn. So the motors 104 themselves not onlyprovide the forward motion for the car 100 but also all the turningability of the car 100. As for the air conditioning, the air leaving theregulator of the air cylinder 106 is extremely cold, freezing in fact.This property will be exploited for cooling of the cabin.

The major problem with the electric alternatives is that they generallyrequire costly limited-lifespan batteries, either on their own orcoupled to a fuel cell. With a battery electric car, the disposal of thesystem at the end of its life can cause issues with heavy metals placedinto landfill especially in developing countries (places like China &India). In the urban areas of China during 2004, 190,000,000 tonnes ofmunicipal solid waste was produced; this is expected to reach480,000,000 tonnes by the year 2030. No other country has everexperienced such a rapid increase in waste generation.

Even in countries like America there are some staggering statistics withregard to the recycling of rechargeable batteries. The U.S. EPA notesthat in 1995, even though batteries made up less than 1% of municipalsolid waste, they accounted for 75% of the cadmium (from Ni-Cadbatteries) found in municipal solid waste. In California during the year2001, 507,259,000 smaller primary (non-rechargeable) and secondary(rechargeable) batteries were sold. Of these only 0.55% was recycled.

Compressed air was therefore chosen as the ideal powertrain 102 for itsflexibility, simplicity, available infrastructure and costeffectiveness.

Rotary Compressed Air Motor Design

The biggest initial negative perception of a compressed air powertrain102 is the size of the compressed air cylinder/tank 106.

There are two main ways to reduce the size of the air tank 106 in apneumatic vehicle 100, these being:

-   -   To increase the tank pressure;    -   Use heat to expand the air in the lines to the motors 104.

The tradeoffs with these solutions are:

-   -   Increased tank pressure:        -   Need for more exotic materials;        -   Increased cost;        -   Increased complexity;        -   Bigger more expensive compressors;        -   Increased weight.    -   Use of heat to expand air:        -   Requires a either a fuel source to burn or a material to            store heat;        -   Produces some carbon emissions;        -   Requires a second pressure vessel or tank 112, hence added            cost;        -   Added complexity.

Looking back at the original criteria for choosing a powertrain source,it was decided to go with a standard pressure and to introduce aflexible burner 110 to the system. The burner 110 is flexible becausethe burner system can be changed to suit the availability of a fuelsource depending on where the car is marketed in the world. This meansthat the burner 110 could be optimized to run on: bio fuels, solidfuels, decomposition by-product gasses (like methane collected fromanimal manure or waste degradation), propane, etc. Compressed NaturalGas (CNG) was chosen as the primary burner fuel source. CNG burnscleanly, can produce a large amount of heat energy and is cheap to buyin thousands of locations already. The other major marketing advantagewith natural gas is that it is already plumbed into over 52% of allhomes across the US. According to the U.S. Censor Bureau, 70% of all newhomes in 2003 used natural gas for heating. This allows house occupantsto own their own filling station, something that is already readilyavailable. FIG. 12 shows a current model home filling station, alreadyon the market and installed in many homes.

Due to the large volume of the air tank 106, a practical place that itcan be situated within the pneumatic vehicle 100 is down the center ofthe car 100. The tank 106, being a very stiff member, can now beincorporated into the chassis and vehicle structure, as detailed in theVehicle Body and Structure section. This provides a stiff ‘back bone’ tothe structure of the car 100, as well as being a practical pressurevessel 106.

The pressure in the tank 106 is 5000 psi (345 bar); this was chosengiven the range of compressors available. At this pressure there aremany options for the physical size of the compressor, the power of thecompressor and also recharge time needed. The size of the compressed airtank 106 required is 60 liters (calculations shown later), from this wecan look at recharge times and costs. FIG. 13 illustrates the costversus time to fill the tank 106 from completely empty to full. However,as the time and cost decrease, the capital cost of the compressorincreases significantly.

Due to the physical size and pressure of the tank 106 and thesignificance of keeping weight down, a composite wound aluminum tank 106is adequate. FIG. 14 depicts different material layers that make up thetank 106.

The aluminum in the cylinder 106 provides the initial airtight cylindershape to filament wind carbon fiber 116 onto as well as the ability tothread in regulators and other plumbing into the neck of the bottle. Thecarbon fiber 116 is then wound onto a spinning aluminum section atoptimum angles to resolve the forces through the tank 106; this is wherethe tank 106 gets additional strength. The final layer 118 of the tank106 comprises of fiberglass and aramid fibers (Kevlar), this providesthe toughness and ensures stones and other debris that could possibly bethrown up from the road do not affect the integrity of the carbonstrength layer.

Composite air cylinders 106 also provide greater safety in the unlikelyevent of an accident severe enough to rupture the tank 106. Aluminum andsteel cylinders tend to rupture violently releasing all the encapsulatedenergy at once, FIG. 15 shows the failure of an aluminum scuba tank. Incontrast, composite cylinders 106 behave differently, with a tendency tofail along a corkscrew pattern around the tank 106. This is because itis easier for the crack to propagate between windings rather thanbreaking the winding. This allows for the contained energy to bedissipated over a longer duration with the tank 106 still holdinggeneral form. The composite tank 106 reduces the effect of an explosion,as well as the risk of flying shrapnel.

The regulator 120 is of a common range, making it cheap to obtain. Theregulator 120 is located in the neck of the cylinder 106 to avoid thepossibility that air could leak from the cylinder 106 uncontrollably, orthat the regulator 120 could be damaged during a collision. This is acommon failure that occurs with both medical and dive cylinders ifdropped. The regulator 120 also incorporates a pressure relief valve andsolenoid. This avoids any chance that the cylinder 106 could be overfilled causing damage or failure of the pressure vessel 106.

Emissions (Burner)

Natural gas is one of the cleanest fossil fuels, due mostly to itssimple molecular composition. The major emissions from the combustion ofnatural gas are carbon dioxide and water vapor. Compared to thecombustion of oil, natural gas emissions have considerably lower levelsof nitrogen oxides and sulphur dioxides and almost no particulatematter. FIG. 16 shows the great reduction in the major greenhouse gassesthat natural gas offers over the combustion of oil or coal.

When burning natural gas in a typical combustion engine, there aresignificant environmental gains that can be made. The U.S. EnvironmentalProtection Agency reported that in a direct comparison to gasoline,possible reductions in emissions are:

-   -   90 to 97 percent reduction in carbon monoxide;    -   Carbon dioxide reductions of 25 percent;    -   Reductions in nitrogen oxide emissions of 35 to 60 percent;    -   Potential reductions in non-methane hydrocarbon emissions of 50        to 75 percent;    -   Fewer toxic carcinogenic pollutants;    -   Little to no particulate matter produced;    -   No evaporative emissions.    -   (Source: http://www.eere.energy.gov/afdc/pdfs/epa_cng.pdf).

If wanted or needed, the pneumatic vehicle 100 can operate without theburner 110 operating, effectively creating a zero emissions pneumaticvehicle 100.

Analytical Thermodynamic Calculations.

The tank size can be calculated using the following defined values:

Tank Pressure (air), P0 34.474 MPa Tank Pressure (CNG) 20.684 MPa LinePressure 0.655 MPa Ambient Temperature, T0 20° C. Temperature dropthrough regulator, T1 −20° C. (a) Temperature increase in burner, T3400° C. Volume of air for one cycle of motor, V3 255 cc Polytropicexpansion efficiency of motor, η 0.85 (b) Polytropic expansioncoefficient, n 1.35 Runtime for 200 km range, t 2452567 s (c) Motor rpm472.58 rpm (d) Natural gas burner efficiency 0.85 (a) Vehicle weight(fully laden) 530 kg

Where the reference letters above indicate;

a) Assumed value

b) Known value

c) Accelerating from standstill to 50 km/h and maintaining till 200 kmoverall distance is covered.

d) Whilst running a 185/35 R17 tire.

Using the equations and theories stated in FIG. 17 the following resultsare calculated:

-   -   The capacity of the compressed air tank 106 is 59.65 L;    -   The amount of heat energy is 184.3 J per revolution, which gives        a total of 20,905,259 J for 200 km distance;    -   The capacity of the compressed natural gas tank 112 is 2.19 L;    -   The distance that can be traveled out of a 60 L capacity        compressed air tank 106 using no natural gas or burner 110 is        approx 71 km;    -   Carbon emissions for the same 200 km journey are 6.84 g/km.

The Rotary Air Motor

The rotary air motor 104 of FIG. 18 is based on a rotary piston. It usesa simple cylindrical rotary piston which rolls, with minimal friction,inside the cylindrical stator. The space between stator and rotor isdivided into a series of expansion chambers, where the air is injected.This drives the piston in a rotary motion over a thin cushion of air.Timing and duration of the air inlet and exhaust is governed by aslotted timer which is mounted on the output shaft and rotates with thesame speed as the motor 104. Variation of performance parameters of themotor 104 is easily achieved by varying the time during which the air isallowed to enter the chamber. Motor speed and torque are simplycontrolled by throttling the amount or pressure of air into the motor104. The rotary air motor 104 gives instant torque at zero RPM and canbe precisely controlled to give soft start and acceleration control.Their small size, lightweight and compactness aids in the integration ofall components in the car. Not only do they serve as device to createmotion, but as suspension components, with one located in each frontwheel 114.

The Burner

The burner 110 consists of a simple proven design, similar to that foundin many other applications. FIG. 19 shows the exploded view of thecomplete burner assembly 110.

The burner 110, like the rest of the car 100, was designed to be simplewith minimal maintenance requirements, low part count and reliable. Asmall draft blower fan 122 moves the hot air through the system and thisensures that all fumes are pushed through the exhaust 124 to the rear ofthe car 100. The inherent design of burner jets 126 is similar to acommon venturi burner, in that there is no need for forced air inductionto maintain a flame.

As far as controls go, the burner 110 will self ignite when required andswitch off when not required, like at traffic lights and when in trafficcongestion. The burner 110 ignites once the pneumatic vehicle 100 hasbeen moving above a particular speed for a predetermined duration. Theburner flame will be a small and steady spread over seven jets 126 toprovide nice even heating to the heat exchanger 108. FIG. 20 shows theburner assembly 110 with the housing removed.

As mentioned earlier in the report, the burner 110 is not required forthe pneumatic vehicle 100 to operate in large cities where it may meanthat no emissions from vehicles are allowed. For this the pneumaticvehicle 100 can turn off its burner 110 and travel a reasonable distancewithout emitting a single emission from the pneumatic vehicle 100.

The heat exchanger 108 is a counter flow design heat exchanger 108making it efficient and compact. The flow diagram is shown in FIG. 21.

HVAC System

A Heating, Ventilating and Air-Conditioning (HVAC) System 128 for thepneumatic vehicle 100 is not a typical Heating, Ventilating and AirConditioning system, because there is no true air conditioning in thepneumatic vehicle 100. The cooling is a result of the pressure changefrom the cylinder 106 to the burner 110. The cold air is conveyedthrough a heat exchanger 129 for cooling air to the cabin. Such a largepressure drop produces very cold temperatures. FIG. 22 shows therelationship and integration with the burner system 110.

A heating system 130 of the HVAC system 128 involves a waste heatrecovery radiator 132 to capture any remaining heat left in the exhaustsystem 124. This is done by re-routing a majority of the exhaust system124 with a restrictive solenoid valve 134 also shown in FIG. 23. Adescription of the parts is shown in FIG. 24. An HVAC fan 136 blows airthrough either radiator 132 depending on user inputs to a car controlunit (CCU), at the same time the restrictive solenoid 134 will onlyengage when heating is selected.

The Packaging

The packaging of the powertrain 102 within the pneumatic vehicle 100 isintegrated neatly into the structure's floor 138. This results inminimal intrusion into both the passenger compartment and also thestorage compartments. FIG. 25 shows the placement of the powertrain 102system within the pneumatic vehicle 100.

Vehicle Dynamics

Simplicity, integration and lightweight are the functional designtargets of the vehicle dynamics system of the pneumatic vehicle 100. Byensuring components serve multiple purposes, through design integration,which has aided in reducing cost and weight, resulting in a simple buteffective solution. The desires for a small, nimble and agile vehicle100, well suited to bustling cities of today and the future, hasprompted the decision for a three-wheel pneumatic vehicle platform 100.Integrating the two direct drive hub motors 104 allows for theimplementation of a simple speed differential steering system 140. Bysimply and precisely controlling the speed of each wheel's hub motor 104allows the pneumatic vehicle 100 to steer; this combined with a trailingsingle rear wheel 142 allows the pneumatic vehicle 100 to turn on thespot, making it easy to navigate through congested city streets and intotight parking spaces with ease. At higher speeds, to ensure thepneumatic vehicle 100 is stable, the rear wheel 142 is actively dampedby a rotary steering damper 144. The entire vehicle dynamics system isprecisely controlled by a Car Control Unit (CCU), which makes the tuningthe handling characteristics extremely flexible.

Vehicle Platform

Three wheel vehicles are currently becoming more popular throughout theworld and are quite prominent in many Asian based countries. Oftentermed a tri-car or cycle-car due to its commonalities between a car anda motorcycle, three wheel vehicles have the scope to be extremelylightweight, fuel efficient and yet very versatile for many urban orcity residents. The three wheel platform inherently lends itself to thedesign philosophy of simplicity and total integration, whilst allowingfor excellent maneuverability, through its steering system 140, whichutilizes the two rotary air motors 104 as its steering device 140.However, careful approach to the design must occur in order to cater tothe three wheeler's inherent dynamic characteristics. Poorly engineeredthree-wheel vehicles can have problems with roll-over stability; whereasa well designed three wheel vehicle 100 can have a roll-over stabilityand superior steering response to that of traditional four wheel. Thisoccurs due to the reduced Yaw moment, which aids in the agility of thepneumatic vehicle 100.

Vehicle Footprint

Given the desire for a small and nimble vehicle, the selection of thewheelbase, track and overall vehicle dimensions are factors. A smalloverall size achieves two of the design targets, lightweight and highmaneuverability, whilst also complementing a reduced overall vehiclecost. Benchmarking against competitor vehicles in the micro/small carcategory provided an initial overall sizing, however, refinement of thepneumatic vehicle's 100 sizing specification was revised throughout thedesign to ensure suitable packaging, roll-over stability and appropriateweight distributions were achieved.

FIG. 26 shows the overall pneumatic vehicle 100 size, wheelbase andtrack. The sphere indicates the location of the center of gravity (CoG)for a fully laden pneumatic vehicle 100 (with two 90^(th) percentilemale front occupants) as determined from a CAD modeling package.

Roll-Over Stability

A design factor of the three wheel pneumatic vehicle platform 100 is itsstability in roll-over. A simple approach has been taken to model thepneumatic vehicle's margin of safety against rollover, by constructing abase cone using the CoG and its location within the pneumatic vehicleenvelopes wheelbase and track. By projecting the maximum turn forceresultant allows the assessment of the rollover threshold as indicatedby FIG. 27.

Model details and assumptions:

-   -   Total vehicle mass (laden)=541 kg    -   Front Track=1500 mm    -   Wheelbase=2500 mm    -   CoG location (x=−29.80, y=510.24, z=−854.37)

FIG. 27 illustrates a rollover threshold of 0.99 g for the pneumaticvehicle 100. Assuming a tractive circle of 0.6 g, which is indicative ofgrip levels for a small passenger vehicle, allows for a 39% safetymargin. This means the pneumatic vehicle's tires will slip, before therollover threshold is reached, ensuring vehicle stability. FIG. 28displays some comparative rollover thresholds for other four wheelvehicle types, indicating the pneumatic vehicle 100 exhibits suitablestability.

Steering Dynamics

The pneumatic vehicle 100 exhibits excellent agility through its frontdifferential steering system 140 combined with its single rear trailingwheel 142, allowing it to ‘turn on the spot’ as illustrated in FIG. 29.Differential steering is employed on many small robots and trackedvehicles, it is often called skid-steering, as it will ‘skid’ the tiresto allow the vehicle to turn. However, with the pneumatic vehicle 100three wheel platform, combined with the single trailing rear wheel 142,no wheels 114 are required to skid, helping ensure tire longevity. Thisis due to the Yaw axis existing between the front wheels 114, unlikethat of tracked vehicles. For high speed stability, the active rotarysteering damper 144 helps stabilize the oscillations and reduce thesweep angle of the rear wheel 142, providing smooth high-speedcornering.

Front Differential Steering

The integration of the two rotary air motors 104 as direct drivemechanisms for the front wheels 114, allows the implementation of adifferential steering system 140 with ease. Controlling the air pressureand flow rates to each wheel motor 104, via independent pressureregulator valves (PRV), accelerates or decelerates the appropriate wheel114 as required, prompting the pneumatic vehicle 100 to steer. Thiscombined with individual wheel speed sensors, which form a feedback loopto the CCU, allow for precise control of steering maneuvers. Due to theentire drive-by-wire system, should the activation of braking berequired to help steer the pneumatic vehicle 100, this can be activated.

Single Trailing Rear Wheel

The single trailing rear wheel 142 provides the pneumatic vehicle 100with its nimbleness at low speeds, as it will simply trail due to thegeometrical offset 146 between the steering axis 148 and the wheelcenter axis as indicated in FIG. 30. This caster trail allows the rearwheel 142 to suitably follow the driving path created by the frontwheels 114. Too little trail causes instability at high speeds and toolarge trail reduces the ability of the wheel 142 to change directionquickly, reducing agility at low speeds. Too large a trail alsoencroaches on the rear packaging space of the pneumatic vehicle 100, asthe rear wheel 142 should have suitable space to rotate a full 360°about its steering axis 148, especially when engaging the pneumaticvehicle 100 into reverse.

To determine the required rear wheel trail and to validate the pneumaticvehicle steering dynamics, a 1/10th scale remote controlled prototype150 was manufactured as shown in FIG. 31. This allowed the trial of anumber of rear wheel trail configurations, to determine the point atwhich the pneumatic vehicle 100 became stable, yet nimble. A qualitativeapproach was adopted, whereby the success of different rear trailcombinations was gauged by the compromise between stability at highspeeds and agility of the pneumatic vehicle 100 at lower speeds. Thefinal chosen geometry is represented in FIG. 30. Further refinement andtuning of the rear suspension geometry could be performed via simulationor a full-scale prototype to ensure optimum handling performance.

Rotary Steering Damper

To provide steering stability and control, a rotary steering damper 144has been integrated into the rear suspension system. The rotary steeringdamper 144 operates using the same principles as a conventional lineardamper, however, rather than damping vertical movements, it stabilizesthe horizontal movements and oscillations of the wheel 142. This is toensure that at high speeds the pneumatic vehicle 100 maintains itsstability and does not erratically spin, due it trailing rear wheel 142.The technology has been employed on the front handlebars of manymotorcycles for the very same reason and has proven results as shown bya known Motorcycle brand, Scotts (www.scottsperformance.com).

To allow the pneumatic vehicle 100 to turn-on-spot at low speeds, theactivation of the rotary steering damping effect is non-existent, asthis will allow the rear wheel 142 to oscillate a full 360 as required.However, as pneumatic vehicle speed increases, the damping effect and areduction of the wheel's sweep angle occurs, as shown in FIG. 32.Utilizing the drive-by-wire system and current magnetic Theologicaldamping technology this is automated and controlled via the central carcomputer (CCU).

Front Suspension System

Several front suspension types were considered, including McPhersonstrut, torsion beam and a transverse leaf spring, however, thedifferential steering system 140 eliminates the need for any toe changefor the front wheels 114, which allowed the integration of a simplesymmetrical double wishbone front suspension 152. The double wishbonesystem 152 allowed for excellent packaging, whilst ensuring the weighttarget was met and aided in contributing to the final low CoG. FIGS. 33a and 33 b shows the front double wishbone suspension system 152, whichintegrates the rotary air motor 104 as the suspension upright.

Integrated Upright/Rotary Air Motor

The applications of a direct drive hub motor 104 allows for simplepackaging and integration as the suspension upright as shown in FIGS. 33a and 33 b. This simple suspension assembly 152 eliminates the need formany complex bearings and ball joints, all of which add to the pneumaticvehicle's cost and weight. The wheel hub and output drive shaft are alsointegrated as the one component 104 as illustrated in FIG. 34 accordingto at least one embodiment, which is beneficial to the pneumaticvehicle's unique steering system 140.

Lower and Upper Wishbone Design

Both upper and lower wishbones 154, 156 are symmetrical about theiroutboard pin joint 158, 160, this eliminates the need for left and righthand versions aiding in reducing vehicle part count and in turn toolingcosts. The elimination of traditional ball joints to allow for toechanges, allows for a simple common bush to be substituted into theinboard and outboard suspension hard points for damping of noise andvibration.

The simple form geometry of the lower wishbone 156 allows for theproposed stamping of an AHSS (Dual Phase 800 MPa grade steel), which hasa higher strength to weight ratio, than conventional HSLA (high strengthlow alloy) materials. This provides suitable structural integrity as itcarries a larger load than the upper wishbone 154, due to the dampermounting position. FIG. 35 shows the lower stamped wishbone assembly 156with its simple bushing 162 arrangement. The upper wishbone 154 carriesa lesser load than that of the lower wishbone 156 and is therefore castfrom an Aluminum Alloy, which aids in reducing vehicle mass.

Upper Wishbone and Damper Mounting

The upper wishbone 154 and damper mount 164 are cast from an aluminumalloy and adhesively bonded to carbon fiber crash tubes 166 of a chassis168 of the pneumatic vehicle 100. A carbon fiber strut brace 169 isconnected to the damper mounts 164 for additional stability. Once againboth left and right hand version are identical, which aids in thepneumatic vehicle's simplicity and are displayed in FIGS. 33 a and 33 b.

Front Suspension Sub-Frame

Modularity of the pneumatic vehicle 100 is enhanced through theimplementation of a front lower sub frame 170, which attaches anddetaches easily to the pneumatic vehicle's chassis 168 through a seriesof mechanical fasteners. This permits the assembly of the frontsuspension 152 independently to the pneumatic vehicle's chassis 168. Thesub frame 170 also serves as the front mounting floor for the powertrain102 assembly which is concealed by the structure's floor, once againattributing to the design philosophy of total integration.

The front suspension sub-frame 170 is manufactured from a lightweightglass fiber reinforced thermoset plastic (GFRP). This material setupallows for accurate fiber management to be achieved, whereby the fibersare orientated in the direction of the load paths. Utilizing a RTMprocess outlined in the vehicle body and structure section permits aflexible, low cost manufacturing process. Finite element (FE) analysisto optimize the materials thickness and glass fiber layer direction canbe employed.

Rear Suspension System

A rear suspension 172 takes on a similar appearance to that of amotorcycle, due to the single rear wheel 142 which is mated to thestructure by a pair of upside down telescopic shock absorbers 174. Therear suspension system 172 comprises of a small number of components, awheel hub 176, telescopic forks 174, a fork crown 178, a steerer tube180 and rotary steering damper 144, as illustrated in FIG. 36. The rearsuspension system 172 can also be independently assembled, and thenattached to the pneumatic vehicle's structure via the steerer tube 180,promoting a modular design.

Upside Down Telescopic Forks

A pair of upside down (USD) telescopic forks 174 accommodate for therear suspension 172 travel. An upside down fork 174 differs from that ofa traditional telescopic fork in that it is inverted, with its tubeslocated at the bottom and the bodies at the top. This achieves a reducedun-sprung mass and also has improved load carrying abilities to atraditional fork of the same mass, helping reduce the mass of the rearsuspension assembly 172. Both telescopic forks 174 are identical,housing both a coil spring 182 and damper 184 (FIG. 36); as opposed toother applications where one side houses a spring and the other housesthe damper.

Braking System

An electro-hydraulic braking (EHB) system 186 is illustrated in FIG. 37and employed on the pneumatic vehicle 100 and comprises of a pair ofsingle hydraulic floating piston calipers 188 attached at two diskrotors 190. When braking is required, an electronically controlledlinear actuator 192 applies the appropriate pressure on a brake mastercylinder 194, which may be located on a firewall of the chassis 168, allof which is controlled by the CCU, depending on how hard the brakingapparatus is pushed or pulled. Through integrated software developmentan antilock braking system ABS can easily be employed, by controllingthe pulse width modulation of the electronic linear actuator 192.

For braking safety, a double circuit master cylinder 194 has beenimplemented. This ensures that if a brake line fails, the secondarycircuit provides a small amount of braking ability, to bring the car 100to a stop safely as illustrated in FIG. 38.

To ensure the pneumatic vehicle 100 conforms to Australian DesignRegulations (ADR), which states the vehicle must come to a stand stillfrom 35 km/h in 11 m, the required braking force was determined andappropriate sizing of master cylinder 194 and caliper piston 188determined.

Rear wheel braking is supplied via a regenerative braking rear hub 196,which slows the rear wheel 142 by converting the kinetic energy into anelectrical current, which re-charges the battery source of the pneumaticvehicle 100 (as outlined in the electronics/human machine interfacesection). Due to the pneumatic vehicle's CoG existing quite close to thefront wheels 114, only a small proportion of rear braking ensures thatthe pneumatic vehicle 100 retains steering stability under braking.Should further investigation show that a rear friction brake is desired,this can simply be added and connected to the existing EHB system 186.

Braking System Calculations

To ensure the pneumatic vehicle 100 conforms to Australian DesignRegulations and the pneumatic vehicle brakes to stand-still from 35 km/hin 11 m, the required deceleration of the pneumatic vehicle 100 is,assuming a tire coefficient of friction, μ, of 0.6:

$s = {\frac{1}{2}{a\left\lbrack {U^{2} + \frac{a^{2}t^{2}}{4} - {Uat}} \right\rbrack}}$

where

s=11 m;

a=9.81 (g)×0.6=5.886 m·s⁻²;

U=35 km/h=9.72 m/s;

Braking Force Required, F_(B),=ma=500 (kg)×5.886 (m·s⁻²)=2943 N, meaningapprox 1500N of braking force for each front brake.

To find the pressure needed in the hydraulic brake line, p_(l), thisequation is used;

$F_{B} = {2\left( {p_{1} - p_{0}} \right)A_{wc}\eta_{c}{{BF}\left( \frac{r}{R} \right)}}$

Where

Braking force, F_(B)=3000 N;

Push out pressure, p₀=50,000 N;

Braking factor, BF=2μ_(L)=0.9 (coefficient of friction is 0.45);

Radius of disk, r=130 mm;

Radius of wheel, R=280 mm;

Wheel cylinder area, A_(wc)=7.187×10⁻⁴ m², multiplied by 2 for bothbrakes;

Wheel cylinder efficiency, η_(c)=0.8 (assumption);

Therefore p_(l)=3.17×10⁶ N/m².

This means that the linear electric actuator 192 that acts on the mastercylinder 194 needs to produce approximately 460 psi to bring the car 100to a stop. If the diameter of the master cylinder 194 is 20 mm, then theforce the actuator 192 will produce is 1000 N, or 225 lbs, which issuitable for the braking force required.

Mass Comparison

Through the implementation of advanced materials, manufacturingprocesses and integrated design, a significant weight reduction of thepneumatic vehicle's suspension systems 152, 172 has been achieved, withthe entire front, rear suspension 152, 172 and braking assembly 186totaling, 98.243 kg. This also includes the rotary compressed air motors104 which are part of the powertrain 102 system.

A recent consortium of auto-makers embarked on the development of anUltra-light Steel Auto Body (ULSAB) Advanced Vehicle Concept (AVC) whichachieved a large overall vehicle weight saving from traditionalvehicles, and had a suspension and braking assembly mass of 182.05 kg.The pneumatic vehicle suspension system 152, 172 of the depictedembodiment achieved a weight saving of approx 54% from a leadinglightweight design.

FIG. 39 provides a parts list for the front suspension assembly 152; andFIG. 40 provides a parts list for the rear suspension assembly 172.

Vehicle Design-Vehicle Dynamics

Innovative integration of two independently controlled direct drive hubmotors 104, a three wheel pneumatic vehicle platform and a uniquesteering system 140, revolutionizes the dynamics of current vehicles.The small footprint and agile steering system 140 of the pneumaticvehicle 100 allows the pneumatic vehicle 100 to turn-on-spot, makingnavigation through congested cities a breeze. Employing a symmetricaldouble wishbone front suspension system 152 promotes simplicity, aidingin reducing weight and the pneumatic vehicle's cost. All of whichcontribute to the design philosophy of lightweight, practical,innovative and simplistic.

See Tables A1 and A2 for parts lists of the Front Suspension Assembly152 and the Rear Suspension Assembly 172.

Vehicle Body & Structure

The pneumatic vehicle 100 and body structure were designed with carefulconsideration of several attributes to ensure that our performance anddesign targets were met. These attributes were:

-   -   Occupant safety    -   Manufacturability    -   Cost    -   Weight    -   Structural rigidity    -   Modularity    -   Packaging    -   Sustainability

Our design philosophy of “integrated simplicity” continued strongly intothe pneumatic vehicle body and structure, such that the design factorsof each of the above design attributes could be met. The use of newand/or non-traditional materials and manufacturing processes wereenablers for the successful design.

The Concept

The design of the pneumatic vehicle body and structure concept isfocused around distinct upper and lower vehicle assemblies 198, 200(FIG. 41). The lower assembly 200 can be considered essentially as arolling chassis 168, providing a large portion of the pneumaticvehicle's strength, stiffness and energy absorption capabilities, whilstthe light-weight upper assembly 198 forms most of the exteriorcomponents of the pneumatic vehicle 100.

There are significant advantages associated with this two-assemblyconcept, as compared to the current monocoque approach. Firstly, thefact that the structural members are independent of the “stylized”exterior components allows the use of much simpler and more structurallyefficient components, thus providing large weight savings. The simplershapes also allow the employment of lower cost manufacturing processesand higher strength materials. These combining factors result in asignificant reduction in the overall cost and weight of the pneumaticvehicle 100, whilst still maintaining excellent structural performance.

Another advantage of the separate rolling chassis 168 is the degree ofmodularity and flexibility of exterior shape that it provides. Most ofthe exterior panels can be changed with very low new tooling costs, andwithout affecting the structural integrity of the pneumatic vehicle 100,thus allowing the pneumatic vehicle 100 manufacturer to quickly respondto consumer demand. There are similar benefits in terms ofrepairability, where exterior panels can be easily replaced, in the caseof a minor vehicle accident. These attributes are primarily enabled bythe use of fiber reinforced plastic for the exterior, manufactured usingthe Resin Transfer Molding (RTM) process. This allows an extremelylightweight design, with low tooling and manufacture costs.

The lower vehicle structure 200 and upper vehicle body 198 will bediscussed in further detail, with particular reference to theengineering design and how each of the attributes of occupant safety,manufacturability, cost, weight, structural rigidity, modularity andpackaging were addressed.

The Lower Vehicle Structure

The lower vehicle structure 200 has been designed withmanufacturability, stiffness and crashworthiness as primaryconsiderations, whilst ensuring that cost and weight were kept to aminimum through an efficient engineering design. The lower structure 200consists of several components, as illustrated in FIG. 42, and weighs atotal of 92 kg. This section will describe the features of the maincomponents in more detail. Refer to FIG. 43 for the parts listpertaining to the lower structure 200.

Materials and Manufacturing Processes

In order to achieve significant reductions in cost and weight overtraditional automotive body-in-white concepts, the lower vehiclestructure 200 extensively utilizes ultra high strength steels (UHSS),combined with selective use of carbon fiber reinforced plastic (CFRP)and aluminum alloy structures. The material and manufacturing processesemployed in the lower structure 200 are summarized in FIG. 44.

As previously stated, the main components of the lower structure 200consist of very simple shapes, due to the fact that these components arenot controlled by the often complex styling of an automotive exteriorbody. These simple shapes permit the use of low cost manufacturingprocess and very high strength materials.

Traditionally, automotive structural components are manufactured usingthe stamping process, which requires the sheet steel to have significantamount of ductility, thus limiting the strength of the material. Byusing simpler shaped components, which have constant or near-constantsections throughout their length, the roll forming process can beadopted. Roll forming requires significantly less ductility; thereforemuch higher strength grades can be employed.

The automotive industry has been using roll forming for many years inorder to manufacture long straight sections, due the large costadvantages. Recent advances in roll forming technology have now made itpossible to manufacture curved sections or sections with varyingprofiles—such processes are commonly referred to as 3D or flexible rollforming. Therefore, the flexible roll forming process offers the abilityto produce more complex shapes, very efficiently and at high productionrates.

Examples of the shapes achievable, and the machinery/tooling systemrequired for the flexible roll forming process are shown in FIG. 45. Inaddition to the cost saving per part, FIG. 45 highlights that rollforming also presents significant reduction in tooling costs, as thelarge and expensive dies associated with sheet metal stamping are notrequired.

As shown in FIG. 44, the lower structure 200 also consists of two keystampings, made from high strength dual phase (DP) steel, which help totie in some of the roll formed components. These stamped components alsoconsist of simple geometries, thus permitting the use of an ultra highstrength DP700 material grade.

Each of the stamped and roll formed components are not visible from theexterior of the pneumatic vehicle 100. Therefore, since a Class Asurface finish is not required, hot rolled grades of steel can beutilized; thus further reducing the costs over conventional cold rolledsheets.

Air Tank as a Structural Member

Due to the inherent stiffness of a cylindrical pressure vessel, thepneumatic vehicle's air tank 106 has been employed as a structuralmember. The air tank's carbon fiber reinforced plastic (CFRP) structure116 provides excellent strength and stiffness, and therefore forms the“backbone” of the pneumatic vehicle 100. This dual-purpose use of whatis essentially a fuel tank 106, as a structural member, highlights thevalue of our core design philosophy—to achieve an integrated and simpledesign.

In order to take full advantage of the high stiffness of the cylindricalpressure vessel, the air tank 106 is attached to the rest of thestructure at several locations. The method of attachment of the air tank106, shown in FIG. 46, has been designed to ensure that each mount usescommon parts, thus significantly reducing both tooling and individualpart costs.

The air tank 106 is manufactured through a filament winding process,with cast aluminum the mounting “rings” 202 (shown in FIG. 46) attachedto the tank 106 via a single co-curing process, thus eliminatingadditional assembly process. (Note that the details of the air tank 106,and the manufacturing process, are described in more detail in thePowertrain section).

High strength extruded aluminum tubes 204 connect the air tank 106 tothe pneumatic vehicle structure 200, with mechanical fasteners used ateach of the joints in order to permit easy removal of the tank 106 ifnecessary. The aluminum members 204 have been sized and positionedstrategically in order to transmit crash loads to the pneumatic vehicle100, whilst also providing high strength attachment points for the cabinseating.

Front Crash Structure

Crashworthiness and crash energy management were factors for the designof the pneumatic vehicle structure. The elimination of the typicalautomotive engine from the front of the pneumatic vehicle 100 provides alarge degree of freedom with the design of the front crash structure,and therefore allows for much simpler and uncompromised design.

As such, carbon fiber reinforced plastic (CFRP) tubes 166 were chosen toprovide the primary means of energy absorption in the case of a frontalimpact. There are several reasons for the ability of composite tubularspecimens to form excellent crash structures, including:

-   -   the near-ideal cylindrical shape provide excellent structural        efficiency;    -   the high strength and stiffness to weight ratios provide        suitable mounting locations for front suspension components;    -   outstanding specific energy absorption values mean that less        mass of material is required in order to absorb the impact        energy.

Dynamic crush tests have revealed that the specific energy absorption(SEA) of carbon fiber tubes is as much as 5 and 2.5 times the SEA ofequivalent steel and aluminum tubes respectively (see FIG. 47).

These high values of SEA are achieved partly due to the deformation modethat occurs during the crush event. When the CFRP tube is crushed athigh speeds (typical of frontal automotive crash events), a large amountof energy is absorbed due to the way that the tube deforms and fracturesinto extremely small fragments. As shown by the photos at severalinstances during a dynamic axial crush test (FIG. 48), this deformationmode is very stable; thus providing a progressive crush and an almostconstant crushing force. This approximately constant crushing force,combined with the simple cylindrical shape, allows the size of the crashtubes 166 and the design of the surrounding pneumatic vehicle 100structure to be designed quite simply and efficiently.

The front crash structure in the pneumatic vehicle 100 has been designedwith primary consideration of the well-known standard European New CarAssessment Program (Euro NCAP) offset frontal crash test. Finite ElementAnalysis (FEA) techniques were used as a tool to design and optimize thefront structure. By calculating the energy absorption required for thegiven vehicle speed and mass, with the knowledge that the crushing forcetransmitted from the CFRP tubes 166 is approximately constant, a simpleload case for the frontal crash test could be approximated (see FIG.49).

The FEA techniques ensured that the front structure successfully managedthe crash energy, provided good load paths for the forces to betransferred to the rest of the pneumatic vehicle structure, and thusminimized the intrusion into the cabin during the crash event.

The designed load paths for an offset frontal impact, into the lower andupper structures 200, 198, are shown in FIG. 50. It is evident thatthere are multiple load paths into the pneumatic vehicle structure,ensuring that the crash loads are effectively distributed. Inparticular, front support members 206 (which connect a firewall 208 ofthe chassis 168 to the tank 106) have been designed to transmit theloads into the extremely strong and stiff air tank 106. Additionally,the crash tubes 166 are each mounted to the firewall 208 by a crash tubemount 207. Further, a bumper reinforcement 209 is mounted to the crashtubes 166 by another pair of crash tube mounts 207.

The use of CFRP materials in automotive crash structures has beenlimited primarily by high costs. The cost of the CFRP crash tubes 166have been significantly reduced through the development of a novelmethod of manufacture, which utilizes the composite layering process.

The composite layering process is disclosed in U.S. Pat. Nos. 6,149,844,which issued on Nov. 21, 2000 to Graham; and 7,306,692 B2, which issuedon Dec. 11, 2007 to Graham; and International Patent ApplicationPublication Numbers WO2002/058916; WO2006/000382; WO2007/003011; andWO2007/022593; the disclosures of which are incorporated by referenceherein and referred to as the composite layering process. This allowsrapid manufacture, minimal tooling and equipment costs, and dramaticallyreduced the cure cycle times, as compared to conventional manufacturingmethods, as shown in FIG. 51.

Side Structure

The side structure of the pneumatic vehicle 100 is designed to be verystiff, in order to prevent intrusion into the cabin in the event of aside impact. UHSS roll formed rocker components 210, which are designedto be much wider than traditional automotive rockers, perform a majorrole in distributing the loads. The high strength extruded aluminumtubes 204, which are positioned at strategic locations, connect therocker 210 to the air tank 106, as shown in FIG. 52. These aluminummembers 204 also coincide with a joint between a b-pillar 212 (whichsupports a roof cross-member 214) and the rocker 210, and at the jointbetween a rear rail 216 and the rocker 210, ensuring the structuralintegrity of these components during a side impact. As part of theintegrated and simple design, the aluminum members 204 also provide highstrength anchorage points for the cabin seating and seat belts.Additionally, the aluminum tubular members 204 can be produced at lowcost due to the fact that these can be almost used in the as-deliveredcondition, with very little extra manufacturing processes required.

It is evident from FIG. 52 that the aluminum members 204, b-pillar 212and rear rail 216 all provide multiple load paths for the side impactloads to be distributed. These, combined with door and side intrusionprotection system described further on, can provide excellent occupantprotection and crashworthiness.

Rear Structure

A rear bulkhead 218 is connected to a rear end of the rocker panels 210and provides access for refilling the air tank 106. The rear rails 216support a rear suspension mount 220 for being supported upon the rearsuspension 172. A rear cross-member 222 may also be provided on the rearrails 216 for additional transverse support.

The Upper Vehicle Body

The upper vehicle body 198 primarily consists of external “skin” panelswhich have been designed with manufacturability, recyclability andstrength to weight as the primary considerations. Even though they areconsidered as skins, many of these components have a structural purpose.The upper body 198 consists of 7 components as illustrated in FIG. 53,and weighs a total of 63 kg.

Materials and Manufacturing Processes

As mentioned previously in order to achieve significant reductions incost and weight over traditional body-in-white concepts, the uppervehicle body 198 extensively uses polymer composites manufacturedprimarily from the Resin Transfer Molding (RTM) process. Combining thesematerials and manufacturing techniques corresponds to a reduced partcount and ease of assembly. The materials and manufacturing processesemployed are summarized in FIG. 54. For extra information on thesematerials refer to the individual component descriptions below.

The Resin Transfer Molding (RTM) Process

The RTM process will be used to manufacture majority of the largepolymer composite components found on the pneumatic vehicle 100 concept.The decision to use this process was based on its efficiency, low costand ability to be used with thermoplastics. These aspects of course werecompared to other techniques when fabricating parts on a mass scale. Thesystem works by inserting a dry fiber preform 224 between a core 226 andcavity 228 die set. The dies 226, 228 are closed, thus applying pressureon the part 224. Resin 230 and hardener 232 flow through the lines,whereby they combine in a mixing head 234. This premixed solution isthen infused through the fiber 224 and, once cured, the dies 226, 228are opened and the part 224 is released. The components involved in theRTM process are illustrated in FIG. 55. The RTM system can be simplifiedwhen used in conjunction with the thermoplastic CBT system. Being athermoplastic it will start off in pellet form where it will need to beheated before it can be infused.

In order to aid in the curing of these parts, we propose the compositelayer process be used in conjunction with RTM. This will be achieved viaspecially designed metal dies which contain fluid channels to allow forthe heat transfer fluid to transfer energy to the composite componentwithin. This of course can occur whilst the crash tubes 166 are beingmanufactured, in order to take advantage of the one manufacturingprocess. Depending on the efficiency of the dies, the composite layerprocess has the ability to reach heat up and cool down rates of 10°C./min. With these parameters and a rapid cure epoxy, the compositelayer process has proven to cure parts in less than 20 minutes.

Another advantage of the RTM process is its ability to reduce the numberof steps on the workshop floor. The painting process for example iseliminated since a gel coat or surface film can be used to give a goodfinish and color to the components illustrated above. These treatmentsare lined within the cavity die before fiber infusion is conducted.Additionally RTM can produce near perfect shapes, meaning less trimmingsteps are required, not to mention reducing overall scrap.

Fender and Bumper Including Hood

A fender/bumper structure 236 including a hood 238 can be considered asnon structural members. As a result they are manufactured from a glassfiber reinforced thermoplastic (GFRP). Some fiber is used to add someadditional stiffness to compensate for the thermoplastic's low modulus.The same material system will also be used for the interior floor 138.The thermoplastic in question is a CBT resin (cyclic form ofpolybutylene terephthalate), developed by the Cyclic™ Group. The choicebehind this system primarily involved its ability to be used inconjunction with the RTM process. Utilizing one process for majority ofthe upper vehicle body 198 meant the manufacturing techniques could beminimized. Furthermore the CBT system offers fast polymerization timesso that these components can be processed very quickly. They are alsofully recyclable.

Using the RTM technique also has its advantages. The RTM process is ableto manufacture complex shapes, and integration of parts can be achieved.For example the fenders and front bumper can be manufactured as one part236, resulting in a minimal part count. In order to remain consistentwith this simplicity, the front structure 236 will not be permanentlyattached to the lower structure 200, using adhesives. Rather it will belocated and attached by mechanical fasteners. This approach simplifiesthe assembly and ease of removal if circumstances require.

Door and Side Intrusion Protection

In order to continue with our design philosophy of integration, doors240 have been designed as structural members. This has been achieved byusing a new technology, which comprises an innovative, cost effectiveand lightweight hybrid composite laminate. These laminates compriseglass fibers with a high strength metal core, effectively a sandwichstructure.

This system has been produced by the ELACO™ group. Their laminates haveproven to show qualities such as high impact strength and high energyabsorbing capabilities while still maintaining a low density, whencompared with material such as steel. According to ELACO™, theirlaminates are excellent for occupant protection when used in conjunctionwith automotive doors. Less is more in this case, where large bulky sideintrusion members are not necessary.

A-Pillar and Roof Rail

As the name suggests this A-pillar and roof rail structure 242 servestwo purposes in this concept, one as occupant protection in the event ofroll over and two as paths for the loads generated in a front or rearend crash situation. In order to provide strength and stiffness, theserails 242 are manufactured from a glass fiber reinforced thermosetplastic (GFRP). This material setup allows for accurate fiber managementto be achieved, whereby the fibers are orientated in the direction ofthe load paths. FIG. 56 illustrates the load paths transferred throughthe A-Pillar and roof rail member 242 when used in conjunction with thefront crash structure 168 and rear suspension members 172.

An epoxy system has been used since these offer a higher strength andstiffness when compared to thermoplastics. In order to keep the assemblyprocesses down, the roof rails 242 will be bonded to the lower structure200 using the use of adhesives.

Roof and Windshield

The roof 244, unlike conventional cars, also acts as the windshield, andis made from an abrasion resistant polycarbonate. This material wasprimarily chosen as it is able to reduce overall weight. Additionallythese new age polycarbonates offer UV degradation protection, excellentimpact strength and are recyclable. Unlike glass, polycarbonate istough, as it is a thermoplastic, and will not shatter in the event ofroll over. Polycarbonate can be purchased as sheet, and heated andformed into shape.

Rear Quarters and Back Panel

As with the front structure 236, the rear structure 246 can also beconsidered a complex shape made simple by integrating many conventionalpanels into one. Unlike the front structure 236 however, the rear 246has been designed with further structural integrity, where it ismanufactured from a glass fiber reinforced thermoset plastic. Beingstructural it serves a number of purposes. In the event of a rear crashsituation, the rear wheel structure 172 may have a tendency to try andprotrude the divide 246 between itself and the rear seated occupants.Therefore making this divide 246 a structural member lessens thelikelihood of intrusion. In addition considering that this member 246 isbonded to the lower structure 200, it adds strength and torsionalrigidity to the rear of the pneumatic vehicle 100. It also aids indistributing the loads acting through the members 216, 220 it is bondedto. Modularity is greatly improved by the fact that this rear component246 fits over the rear structure 216, 220 as one component. This enablesfuture models to be designed easily using the one platform; for examplea utility or roadster model can be easily produced by changing this andonly a few other components.

Summary of Material Use and Manufacturing Processes

It is evident that a lightweight low cost and high strength vehicle bodyand structure has been achieved through an integrated and simplisticdesign. This is achieved by taking advantage of new manufacturingtechniques and novel materials. These are summarized in FIG. 57.

These charts highlight the significant use of these new processescompared to current methods, such as stamping which is only responsiblefor 10% of the structure. Traditional stamping techniques have beenreplaced with roll forming and RTM processes, which are used tomanufacture almost 50% of the structure. The main advantages theseprocesses have to offer include: reduced cost through a reduction incomplex tooling, increased efficiency through reduced part count, andassembly processes and a significant reduction in weight. In additionthese allow for increased flexibility and modularity in terms of futureconcept designs and the outsourcing of production processes. See FIG. 58for a parts list of the upper vehicle body 198.

Vehicle Interior

A vehicle interior 248 was designed with careful consideration ofseveral attributes to ensure that the car interior 248 was stylish butflexible so that it could appeal to a variety of market groups. Theseattributes were:

-   -   User customization;    -   Manufacturability;    -   Cost;    -   Weight;    -   Variety;    -   Ease of use.

As the interior space 248 is the most interactive part for the user ofthe car 100, our design philosophy of “integrated simplicity” wascombined with the concept of “user customization”. This provided aplatform that could be optimized to suit the owner's needs.

The use of simple interchangeable interior components, as well as plugand play electronics, were enablers for the design.

The Concept

The vehicle interior 248 concept is focused around simpleinterchangeable seat and door trims 250, 252. The interior isrepresented in FIGS. 59 a, 59 b, 59 c and 60. Door trims 252 utilize aquick fix panel system that can be cheaply produced and quickly attachedto the door structure 240. The seats 254 follow a similar concept withan easily interchangeable upper and lower cover 250 that fix to theframe of the seat. This enables damaged, faded or unfashionable seatcovers to be simply replaced with new factory or aftermarket covers 250.Both of these allow the user to quickly adapt a new or used car to theirpreference providing increased satisfaction in their purchase.

The interchangeable door trims 252 also enable a break from thetraditional specification and delivery of interior systems. Currentlythe customer either accepts a standard interior or they order a custominterior that is fitted by the factory with large delays in delivery andcosts to the customer. With the pneumatic vehicle 100 concept, the car100 can be delivered to the dealership and the interior 248 can be addedto the car 100 by dealer qualified fitters. One way for a dealer tospecify out the car 100 would be to have a virtual car package set up onthe internet. The customer could view and interact with the interior 248of the car 100 using the virtual world (this is known as haptics)assessing a range of different interior set ups. This could includecolors, patterns and materials. The interior components would beorderable over the internet and installed by either the dealer or theowner.

Seats

The design concept for the pneumatic vehicle seats 254 is to utilize thesame RTM manufacturing process used for the vehicle's body as a baseplatform to support the inflatable seat adjustment system. See FIGS. 60and 61.

RTM was selected for the seat base 256 as it enables a twin piece seat254 to be made at a relatively low cost. In order to provide strengthand stiffness the seat frame 258 is manufactured using a Glass FiberReinforced Thermoset plastic (GFRP). This material setup allows foraccurate fiber management to be achieved, whereby the fibers areorientated in the direction of the load paths. The base structure 256 isfar simpler than that of a conventional seat as it does not require anyspot welding or steel pressing. The two halves of the seat 254 can bepushed together and held in place by locking points 260 made as part ofthe molding process. This fixing system cuts down the inventory of partsrequired for fixing the two parts together during assembly. Along withthe integrated clip system the integration points for air bladders 262can be provided in the one molding process for the front part 250 of theseat mold. The simple manufacture and assembly process helps to cut thecost of producing the seat 254 and make it more reliable as there areless moving parts.

The GFRP base 256 can be achieved because of the unique air bladdercushioning system 262. The silicone rubber air bladder cushions 262replace the need for springs and polyurethane foam and provide far moredriver adaptability.

The use of low pressure air inflatable inserts 262 within the seats 254allow for a wide range of adjustment with a single pressure controllerand selector valve. The silicone rubber bladders are held in place byclip-in plastic inserts 260 that mount into the front half of the seatframe 258. Sealing is achieved by a thin layer of a silicone adhesivebetween the bladder edge and the seat front. The bladder system 262allows multiple adjustments normally achieved by complex mechanicalsystem.

This system 262 is particularly evident in a rear passenger seat 264,see FIG. 62. This seat 264 is designed to hold either a single adult ortwo children. This is achieved by the inflatable bladders 262 that arepositioned to inflate into a center division forming two small bucketseats. These then deflate to form a bench seat for a single adult.

The elimination of accelerator and brake pedals means that the seats 254can be fixed in a constant position within the car 100. This means thatseat mounts 266 can be simplified to one-piece brackets that have nomoving parts while the driver comfort is achieved through the tilt andprojection of a steering wheel 268.

While fixed to the structure of the car 100, the front seats 254 stillhave a range of hinged movement between the base 256 and back support258. The driver's seat 254 is restricted to a small tilt for adjustingdriver comfort but the passenger seat 270 is allowed a greater range tofold down parallel to the base 256 as in FIG. 63. This creates a flat‘table’ area for extra storage space across the front passenger seat 270and into the rear bench seat 264.

The fabric coatings 250 for the seats 254 complement the interior trims252 and carpets 272 and are easily changeable. The seat 254 does nothave a conventional sewn cover that is permanently attached to the car100. The seat coverings 250 are slipped over a semi-ridged hoop thatstretches down over the inflatable bladders 262 to be fastened at theseat structure 254. One method for manufacturing the base model car seatcover 250 would be using a fully fashioned circular knitting machine.The seat cover 250 knitted using this method would have limited waste;no edge seams and limited requirements for cut and sew. All of thesesavings help to reduce the manufacturing costs. The use of a highstretch textured synthetic filament allows for good conformation overboth the inflated and un-inflated bladder system.

Traditional cut and sew construction could be utilized to allow coversto be made from multiple material types and some of these include wovenfabric, velour fabric, leather and vinyl. This enables a wide variety ofoptions for the consumer to customize their car 100. Like the interiortrims 252 and carpet 272, the seat covers 250 can be changed to suit thelatest fashion or to get rid of staining or dirt.

Floorings

The design of the flooring follows the same concept of flexibility andchoice found in the rest of the interior. The floor pan 138 has beendesigned to be flat with turned up sides that allow for simple pressedflooring shapes. Choice of floor materials is wide providing highflexibility and a wide variety of choices for the consumer. Materialssuch as Polypropylene non-woven fabrics, tufted polypropylene carpet orrubber matting are a few examples that could accommodate end uses fromthe base model, luxury interiors through to a tradesman's vehicle.

The carpet manufacture system is simple. Non-woven mats can have amelt-bonded edge applied to the carpet 272 during pressing to shape.This incorporates two steps into one and provides for a slightly flatteredge that can be inserted easily under the retaining trims. Thenon-woven floor covering is a low manufacturing cost alternative for thebase model car 100.

Rubber matting 276 is designed to insert inside the non-woven mattingfloor, see FIG. 64. The rubber matting 276 can be utilized in many waysincluding as a protective cover when the pneumatic vehicle 100 is usedfor deliveries or by a tradesman. The rubber lining 276 can then beremoved and the car 100 can be used as a family car 100 on the weekendsor for special occasions.

To keep with the concept of adaptability, the flooring 276 can becolored and patterned using digital printers to provide designerflooring 276. This would be unique within the auto industry as theflooring 276 could be designed to match or complement the other parts ofthe interior and once again the low cost non-woven material mattingcould be easily changed to suit the owner's needs.

Door Linings

The door lining 252 consists of two components; a solid panel and adecorative trim. The solid panel is multi functional acting as both amounting point for the door trim 252 and as a sound deadener for thedoor cavity. The decorative trim 252 is adhesively backed and easilyinterchangeable for optimum adaptability of the interior.

The door trim 252 is designed with an adhesive backing laminated to itduring manufacture. It allows for trim selection and fitting at thepoint of purchase or by the customer. The trim can be changed if thecolor fades, becomes soiled from use or just a change in appearance.

Door trims could be made out of a variety of different materials andafter laminating could be cut out with an automated laser cutting andpatterning system. This range of both factory and non-factory trimswould provide flexibility in the interior styling to suit a wide rangeof market types.

Multiple trim materials allow for several levels of interior fit out.These levels would include base model, sports, luxury, tradesman anddesigner. Materials used could include woven textile, velour textile,carpet, leather and plastic film.

The trim system would cut down the inventory of parts required by themanufacturer for the assembly of the car 100. The car 100 would besupplied to dealer without trim and the dealer would hold the inventoryof trim or consumers could order specialized trims from the internet andhave them delivered flat packed in express mail as the shape and weightof the trims would be low.

The solid panel is a clever composite made from a bi-layer air-laidneedle punched non-woven fabric. Air-laid non-woven material has highproduction rates at a low cost. They have the most uniform tensileproperties of all of the non-woven manufacturing techniques as thefibers have a good distribution in both the machine and cross machinedirections. The bi-layer material is selected as it provides a solidlayer for structural conformity and a soft layer for noise deadening.

The difference between the two layers is the ratio of the fibers used.The solid layer is made from a mixture of 50% low melt temperaturesynthetic fiber and the 50% natural fiber. The soft layer is made from amixture of 90% natural fiber and 10% synthetic fiber. In the solid partof the panel the natural fiber is used as reinforcement for the panelafter hot molding. In the soft panel it is used for adsorbing the noisegenerated within the door cavity. The synthetic used could be eitherpolypropylene for low cost or polylactic acid for an environmentallydegradable product. The synthetic is used to bond the natural fiberstogether in both of the layers. In the solid layer the syntheticprovides a solid structure after hot pressing whereas the synthetic inthe soft layer bonds fibers but still allows openness of the layer. Thetwo layers are connected during needle punching and remaininterconnected after the hot compression molding phase of the doorconstruction.

Control Systems

Referring to FIG. 65, an electronic drive-by-wire system 276 that willbe used to control the various systems throughout the pneumatic vehicle100. Using a complete drive-by-wire system 276 allows precise controlover all systems, including the powertrain 102, braking system 186,steering system 140 and other Human Machine Interfaces (HMI). This tiesin with the design philosophy of total integration. Using embedded lowcost devices, a modular system 276 has been developed which allows for aplug-and-play style system of independent interconnected networkedelements, which control and monitor dedicated sub-systems under thecontrol of a master processor, achieving a level of total integration.Like the original Model T which had a production life span of twentyyears, the pneumatic vehicle 100, through the central computer system,allows the ability to plug-and-play hardware and update of controlsoftware with ease, turning the pneumatic vehicle 100 into a flexibleand customizable appliance. In the following sections each element inthe drive-by-wire system will be described in detail.

Car Control Unit (CCU)

A car control unit (CCU) is the master controller within the car'scommunication system 276. Based on a master/slave concept, the masteroversees the high level operations of the lower slave modules which arededicated to individual control tasks. Consisting of a low cost embeddedmicroprocessor, the CCU uses a Local Interconnect Network communicationprotocol (LIN) which comprises of a single wire, which is a much moresimple solution to the current communication methods used in today'smotor vehicles.

The CCU involves tasks such as, defining transmission speeds, sendingsynchronization pulses to the slave modules, data monitoring andrecording within the pneumatic vehicle 100, switching slave nodes tosleep/wake up mode, acting as the central brain of the pneumatic vehicle100.

FIG. 65 demonstrates the drive-by-wire functional diagram showing howthe CCU master is connected to the slaves via the LIN method. In thenext section, the LIN protocol is described.

Local Interconnect Network Communication Protocol (LIN)

The LIN (Local Interconnect Network) is a low cost serial communicationsystem intended for the primary communication method in the distributedelectronic system in vehicles. LIN complements the existing methods ofautomotive communication networks (see FIG. 66) and provides aneffective solution to the embedded control methods within the pneumaticvehicle 100.

In the regular car market, the typical applications for the LIN methodsare in assembly units such as doors, steering wheel, seats, climatecontrol, lighting, rain sensor, etc. In these units, the cost sensitivenature of LIN enables the introduction of mechatronic elements such assmart sensors and actuators to be included as part of the design. Theycan be easily connected to the current car network and become accessibleto all types of diagnostics and control services. For the low cost carmarket, the LIN method can replace the conventional car networks, (suchas CAN), and can enable a cost-effective communication for smart sensorsand actuators where the bandwidth and versatility of CAN is notrequired.

The communication is based on an SCI (UART) data format, asingle-master/multiple-slave concept, a single-wire 12V bus, and clocksynchronization for nodes without a stabilized time base (LIN,http://www.lin-subbus.org/). This method reduces the need for a largewiring harness and cuts the cost of development, production, service,and logistics in vehicle electronics compared to that of existinglow-end SCI based multiplex solutions (as shown in FIG. 66). Although itdoes not operate at high data rate speeds compared to conventionalmethods, such as CAN-B and CAN-A, its master slave concept and one wireinterface allows for this method to be implemented in the low costembedded systems area. With a relatively low communication cost pernode, it is ideal for the low cost car market.

The benefits of the LIN method are as follows:

-   -   Low cost single-wire implementation,    -   Enhanced ISO 9141, VBAT-based speed up to 20 Kbit/s,    -   Acceptable speed for many applications (limited for        EMI-reasons),    -   Single Master/Multiple Slave concept,    -   No arbitration necessary,    -   Low cost silicon implementation based on common UART/SCI        interface hardware,    -   Almost any microcontroller has necessary hardware on chip,    -   Self synchronization in the slave nodes without crystal or        ceramics resonator,    -   Significant cost reduction of hardware platform,    -   Off-the-shelf slaves,    -   Flexibility because of configuration features,    -   Guaranteed latency times for signal transmission,    -   Predictable systems possible, and    -   Easily upgradable with plug and play items.

Safety Control Unit (SCU)

This module is design solely to coordinate the safety features of thecar 100. Features such as ABS, Airbags and seatbelt restraints, alongwith the optional features such as an alarm or a security immobilizerare controlled via this slave processor.

Instrument Cluster and Media-Climate Control Unit (ICMCCU)

This unit controls the main human-machine interface of the car 100. Onceagain using a master/slave concept, the Instrument cluster andMedia-climate control Unit (ICMCCU) commands a sub unit using a LINcluster method. The ICMCCU directly controls elements such as theSpeedometer, indicators, fuel gauge, lights etc by receiving digitalsignals from the appropriate sensors within the car 100, processing theinformation, and sending it to the CCU or an appropriate display unit(positioning shown in FIG. 67 and connection hierarchy shown in FIG.68).

There are two main display units within the car 100, the instrumentpanel, and the Media and Climate center. These are explained in furtherdetail below.

Instrument Cluster

The instrument cluster contains instrumentation and controls pertainingto operation of the pneumatic vehicle 100. Since this system is amodular, drive-by-wire system 276, it can be modified to the usersliking and upgraded easily as the car 100 is upgraded.

Media and Climate Center

The media and climate center is the focal point within the dash andallows the users to interface with the car's heating and cooling system128 along with the sound system. With the use of a low cost touchinterface, the interface screen is free of mechanical knobs and buttonsallowing it to be fully customizable and user friendly. With theaddition of software updates, new features can be integrated throughthis system and extra features such as GPS, pneumatic vehicle diagnostictools, performance measures etc, can be added as new systems becomeavailable.

Drive Train control Unit (DTU)

Once again using a master/slave concept, the Drive Train control unit(DTU) primary function is to oversee the control functions of the twosub systems, the Engine control unit and the Steering control unit. SeeFIG. 69. In addition, the DTU also determines what physical actions areneeded to be taken for the pneumatic vehicle 100 to move. For example,if information from the Steering control unit contains the commands toturn left, and the Engine control unit sends the commands foracceleration, the DTU performs the control actions of open right valvemore than the left valve, and injects hotter air into the system whichwould cause the pneumatic vehicle 100 to turn left at a fast speed.

Engine Control Unit (ECU)

This unit is primarily used to control the various aspects of theengine's operation. The role behind this unit's operation is todetermine the quantity of fuel, pressure control, control heatingsystems 110, 130 and other parameters by monitoring the engine 104through sensors. The monitoring and control of this system is done byusing a control loop such as a PID controller.

For example, this system reads the throttle position and determines theamount of fuel that is needed to be provided to the motors 104. If thethrottle pedal is pressed further down, this information will be sent tothe DTU and this will open the valves and allow more air to be passedthrough the heat exchanger 108 and into the engine.

Steering Control Unit (StCU)

The Steering control unit (StCU) is primarily used to monitor andcontrol three items: to control the rear wheel damping system 144, tocontrol and monitor the regulation of the rear hub 196 power generation,and to monitor the steering position sensor. The StCU reads the positionof the steering sensor in the steering wheel and sends this to the DTUfor the control of the motors 104.

The rear wheel damping system 144 is also monitored and controlled viathe StCU. This system obtains wheel speed sensor readings and eitherstiffens the dampening system 144 for high speeds, or relaxes it for lowspeeds.

Rear Hub Generation Method

For the pneumatic vehicle 100 to have sufficient power, a method ofpower generation is capable of running the onboard electronics. Sincethe rear wheel assembly 142 is free spinning, a regenerative system 196is placed into the rear wheel assembly 142 that uses a geared alternatorsetup to generate power for recharging a battery pack 278.

A geared setup obtains the correct revolutions per minute (RPM) for thealternator 196 to become excited to produce enough voltage. When the RPMfalls below the excitement threshold, the system will no longer producecharge and the battery 278 will become drained. The gearing systemwithin the rear assembly 196 allows for a relatively low RPM to be usedto produce a constant trickle charge throughout driving.

FIG. 70 depicts the connection setup for the power generation whichconsists of two main elements, the Automatic Voltage Regulator (AVR) andCharging Circuitry 280. The AVR converts the varying voltage from thealternator 196 into a usable form for the charging circuitry 280, andthe charging circuitry 280 converts this voltage to charge the battery278. The battery 278 used within the pneumatic vehicle 100 is ofLithium-polymer, or Lithium-ion type which is lighter compared toconventional lead-acid batteries and it can be specifically shaped tofit the housing environment. This technology was chosen for its greatlyincreased run times compared to conventional technologies, and it weightsaving properties.

Future Expansion and Upgrades

The benefit of a drive-by-wire system 276 is that it allows for thetechnology to be upgraded and expanded with relative ease. Extrafeatures such as GPS, cameras, environmental sensing technology, andhead-up displays, etc., all can be added to the current system withoutany major modifications. The advantage of the LIN method allows forsimple, low cost, plug and play modules to be added with relative easeat no cost to the current configuration of the electrical system. Inaddition, if any of the subsystems fail or need to be upgraded, they canbe swapped for another module without hassle.

Business Proposal

This section outlines the pneumatic vehicle's costing and manufacturingprocesses for all the components and assemblies. Moreover, a businessanalysis has been performed regarding the launch of the pneumaticvehicle 100 in the Chinese market.

Manufacturing and Costing Report

The concept car 100 is designed as an entire system that is decomposedinto sub-systems and components as illustrated in FIG. 71. Many of thesystems have already been described previously. This section gives anoverview on all of the systems regarding costs and manufacturingprocesses. Each system has been simplified where possible, and systemshave used revolutionary manufacturing systems to reduce costs andvehicle weight.

Brake System

The concept car 100 comes with a conventional disk brake system 186 forthe front wheels 114. The brake assembly 186 consists of the followingmajor components: brake disk, master cylinder 194, braking solenoid,brake calliper and lining. The whole brake system is a conventionalassembly; it can be outsourced and then assembled on the suspensionsystem 152. The condition of the brake system is readily examinable, andthe components that wear are designed to be adjusted or replaced atappropriate service intervals. The material used for the brake disk 190is cast iron and manufactured by casting process and then machined,drilled and slotted. Ventilated disks are used so as to improve coolingaction. Fixed front axle callipers are used so as they provide ampleinsulation space. The detailed calculations on the brake system can befound in the Vehicle Dynamics section.

Suspension System

The independent double wishbone suspension system 152 is used for bothfront wheels 114. The major components of this suspension system 152(FIG. 72) are the lower and upper wishbones 156, 154 and coil over units282. The material used for the upper arm 154 is a 6061 alloy and it ismanufactured by a casting process. The lower arm 156 is manufactured byroll forming with Dual Phase steel. The cost is reduced by outsourcingthe suspension system 152; this can be done as it is a conventionalsuspension set-up. The rear suspension system 172 consists of twotelescopic forks 174 mounted on both sides of the wheel 142. The majorcomponents of the rear suspension system 172 are the upper and lowertelescopic forks 174 with shocks 184 and coil springs 182 that areassembled to the fork crown 178. The front and rear suspension systems152, 172 are directly assembled to the car 100. The front and rearsuspension mounts 164, 220 are manufactured by casting with castaluminum and 6061 alloy respectively.

Rear Steering System

The rear wheel 142 is allowed to swivel to enable steering. The steeringangle of the rear wheel 142 is controlled by a rotary steering damper144, which reduces the sweep angle and increases damping at higherspeeds. More detail on the rotary steering damper 144 can be found inthe Vehicle Dynamics section. The components manufactured in the rearsteering system are the steering shaft 180 and a lock nut 284. Thesteering shaft 180 and lock nut 284 are cast using chrome stainlesssteel and alloy steel respectively. The rotary steering damper 144 canbe purchased.

Wheel and Tires

The front and the rear wheel rims 286, 288 are cast using a 6061 alloy,and then machined, slotted and drilled, see FIG. 73. The wheel diameteris 17 inches for both the front and the rear wheels 114, 142. A frontwheel hub 290 is cast using an alloy steel, and then machined. Thematerial used for the rear wheel hub 176 is a 6061 alloy, and it ismanufactured using a casting process. The tires 292 can be purchasedfrom a potential supplier.

Body Structure

The body structure comprises of two major sections, a lower section 200and an exterior 198.

Lower Section

The manufacturing processes involved in creating the lower section 200comprise stamping, casting, resin transfer mounding, extrusion,composite layering and roll forming. The firewall 208 and bumper 209 arestamped using a dual phase steel and a martensitic steel respectively.The wheel arches 294, a front access panel (not shown) and front subframe 170 are manufactured using Resin Transfer Molding (RTM). Thematerial used for the wheel arches 294 and the front access panel isglass fiber reinforced thermoplastic resin. Glass fiber reinforced epoxyis used for creating the front sub frame 170. The crash tubes 166 aremanufactured using carbon fiber epoxy composite by the composite layerprocess. The cast components are the crash tube mounts 207 and the tankmounts 202 using cast iron and cast aluminum respectively. Roll formingis used to manufacture the martensitic steel rocker panels 210. RTM isused to manufacture the glass reinforced thermoplastic resin floor 138.

Exterior

The exterior section 198 consists of the bumper 236, the hood 238, twodoors, a door ring reinforcement strip, a front reinforcement strip,several windows, and the roof and rear quarters. The manufacturingprocesses used are RTM and Injection Compression Molding (ICM). A glassfiber reinforced thermoplastic resin is used for the bumper 236, thehood 238, and the doors 240. A glass fiber reinforced epoxy is used forthe rear section 246, the door ring, and the front reinforcement strips242. All these components are manufactured using RTM except for thepolycarbonate roof 244, which is Injection Molded.

Powertrain

The powertrain 102 consists of three units: the drive train 104, the jetburner 110 and the HVAC 128. The main component of the powertrain 102 isthe rotary air motor 104. The motors 104 along with several othercomponents, such as an air line 296, a throttle actuator (not shown),the regulator 120, and the fill tube 106 can be purchased from thesupplier. The cost estimate allowed for the rotary air motor 104 is anestimate based on a review of the motor's use of materials,manufacturing methods and assembly processes. The Air fuel tank 106 andthe CNG tank 112 are created from carbon fiber tube 116 with a filamentwinding. The jet burner unit 110 consists of: an exhaust tube 124, aburner jet 126, a base 298, burner housing 300, a safety valve 302, adiversion valve 304, a silicon manifold 306, and some connection pipes308. The plastic exhaust tube 124 is injection molded, the brass burnerjet 126 is machined, and the base 298 is cast out of cast iron. The restof the components in this unit can be outsourced. The injection moldingprocess is used to manufacture the parts in the HVAC unit 128, that is,the top and bottom housings 300, the dividing valves 304, cabin airducting 310, and a fan housing 312. The detailed calculations on thecompressed air tank 106, the CNG tank 112, and the HVAC unit 128 can befound in the Powertrain section.

Manufacturing Processes

Materials and technologies employed in automobiles reflect the availablestate-of-the-art. The material or method chosen is the one that bestsuits a given set of demands. The properties of individual materialsshow a significant difference in weight, strength, and cost. Steadilyrising demands for safety and expected comfort, increasingly lead tolightweight design; and therefore to appreciably greater application ofplastics and lightweight alloys. Some of the manufacturing techniquesare described in more detail in some of the other system sections.

Resin Transfer Molding (RTL)

One feature of RTM is the complete integration of the reinforcementwithin the composite, such that all the air is removed from the mold.This leaves no dry patches in the cavity. RTM has been recognized as auseful fabrication method for large area panels, often relying uponvacuum assistance for reinforcement compaction and mold clamping in theautomotive industry. The success of RTM has been attributed to greaterflexibility in part design, with more emphasis on componentrecyclability and the reduction of emissions. Due to high volume ofmaterials involved in automotive industry, the RTM material costs arevery low, ranging typically from 20-30%, relative to a figure two orthree times larger for a simple stamping or assembly. This is partlyattributable to the smaller number of parts needed using RTM, than thelarger number when using stamping (see FIG. 74).

The RTM process uses a two sided mold set that forms both surfaces ofthe panel. The lower side is a rigid mold; the upper side can be rigidor flexible mold. The two sides fit together to produce a mold cavity.The distinguishing feature of RTM is that the reinforcement material isplaced into this cavity and the mold set is closed prior to theintroduction of matrix material. The details about the RTM process canbe found in the Vehicle and Body Structure section and in FIG. 75.

Cycle Time: Thermoset resin transfer molding is a good technique for theautomotive industry with an average cycle time of approximately 20minutes. Parts manufactured using the RTM process are listed in FIG. 76.

Composite Layering Process

The composite layering process can be used in the out-of-autoclavemanufacture of advanced composite materials, see FIG. 77. The compositelayer process can be applied to the automotive industry, where strengthand weight are important features. The composite layer process hasreduced cycle time (relative to autoclaving) and product weight, as wellas increasing strength and improving appearance. Moreover, it providesproduct properties superior to conventional curing techniques. Thecomposite layer process data shows reductions of 50% to 90% overautoclave cycle times with high accuracy temperature control.

The component is first laid up by arranging prepreg plies on a moldtool, the mold will not be sturdy since it will be virtually floating inthe heat transfer fluid. The next step is to cover the exposed side ofthe laminate with the vacuum bag and breather layer. The standardprocess then comes to an end as the mold tool is placed in a Compositelayer machine. The component is placed under slight pressure achieved byusing nitrogen gas to pressurize the contents of tanks containing theHigh Temperature Fluid (HTF). The pressure exerted against the bladdercauses it to mate closely with the mold and confirm to its contours.

Cycle Time: Cure cycle times are expected to be between 40-60 minutesfor most resin systems making a big saving over 4-8 hours typicallyrequired in an autoclave. The cycle time can be reduced to 20-30 minutesfor a typical epoxy at 180° C. cycles.

The crash tubes 166 are manufactured by this technology using a carbonfiber epoxy composite. Compared to the conventional autoclave processfor the similar part, the quick step process could make a saving of 65%on its tooling cost.

Roll Forming

Roll forming is a bending shape forming process where a long strip ofmetal (typically steel) is passed through a set of rolls or stands, seeFIG. 78. The bending occurs gradually in several forming steps from anundeformed strip to a finished profile. Each step or stand continuouslyperforms an incremental (low strain) part of the bend. A number ofstands are used in the process until the desired cross section profileis obtained. Long length parts in large quantities are ideally bestsuited for the roll forming process. Continuous trimming and cuttingoperation with multiple configurations can be set up for roll forminglines to separate parts, which reduces time and cost of manufacturing.

This process is very beneficial due to the high speed in which complexprofiles can be produced. High strength steel is the most commonmaterial to be roll formed. Moreover, roll forming is a low strainoperation and enables profiles to be created on sheets with poorformability. For this reason, roll forming is seen as a potentialprocess that can produce automotive parts out of Ultra High StrengthSteels.

Cycle Time: The cycle time can be approximately calculated as 80ft/min×60 min, that would be 4800 ft/hr. FIG. 79 lists partsmanufactured using the Roll Forming process.

Stamping Process

The automotive stamping process is considered as the first step in theproduction of an automobile. In a stamping plant both internal andexternal parts can be produced. Stamping is a simple process where partsachieve their shape from forces applied through the die tooling. Highvolume sheet metal parts can be typically manufactured using thestamping process thus making them economical. The advantages of thisprocess is that they provide suitability to produce small work pieces ata rapid rate and has the ability to save time and money by combiningforming operations. Stamping also maintains close tolerances dependingon the tool selected.

Cycle Time: The parts produced in an hour vary from 100 to 400 dependingon the sheet thickness and the complexity of the part. FIG. 80 listsparts manufactured using a stamping process.

Casting

Casting is a versatile process for producing engineered metal parts byforcing molten metal by gravity or pressure into molds. Parts can bedesigned to produce a complex shape with high degree of accuracy andrepeatability with smooth and textured surfaces. Casting is consideredas a high volume mass production process. Casting provides complexshapes with closer tolerances than many other mass production processes.Little or no machining is required and thousands of identical castingscan be produced before new tooling is required. Castings do not consistof separate parts nor are fastened together, the strength is that of thematerial rather than the joining process.

Cycle Time: The process consists of stages of clamping, injection,cooling, ejection and trimming. The total cycle time is very shorttypically between 2 sec to 5 min depending upon the geometry of thepart. FIG. 81 lists parts manufactured by the injection molding process.

Injection Molding

Injection molding is the most commonly used manufacturing process forthe fabrication of plastic parts. Parts can be manufactured which varygreatly in their shape, size, complexity and application. The processrequires the use of an injection molding machine, raw plastic materialand mold. Plastic is melted in the injection molding machine and theninjected into the mold, where it cools down and solidifies into thefinal part. The cost of manufacturing depends on various factors such asnumber of cavities, size of parts, complexity of pieces, expected toollongevity and surface finish. The main advantages of injection moldingare its ability to produce the parts in a fast paced environment, withvery tight tolerance control, and the ability to produce the product ina variety of materials.

Cycle Time: The process cycle for injection molding is very shorttypically between 2 sec to 2 mins. FIG. 82 lists parts manufactured bythe injection molding process. FIG. 83 illustrates parts purchased andmanufactured with various processes.

Life Cycle Assessment

This report will discuss the effects the pneumatic vehicle 100 may haveon the environment. To assess the impact of this car 100 on theenvironment a number of tools/goals need to be considered which include:

-   -   a life cycle assessment of the pneumatic vehicle 100,    -   material selection for recyclability,    -   manufacturing processes, and    -   the carbon footprint of the pneumatic vehicle 100.

Vehicle as a Whole

The pneumatic vehicle 100 can be assembled in a plant similar to currentpractice. Alternatively, the vehicle 100 can be assembled, customized,inspected, serviced, exhibited, sold and financed at a common facilityas depicted in FIG. 84. However, instead of welding the car's mainstructure (lower and upper vehicle 200, 198) a structural adhesive willbe used. Answers.com defines a structural adhesive as “An adhesivecapable of bearing loads of considerable magnitude; a structuraladhesive will not fail when a bonded joint prepared from the thicknessof metal, or other material typical for that industry, is stressed toits yield point.” This implies that the joint will be as strong as aweld and not have the same stress concentration points as would occur ifusing a fastener.

Life of Vehicle

One advantage that the pneumatic vehicle 100 has is that it has almostzero operating emissions, the only emissions that will come from thisvehicle 100 is from a small CNG heater 110 that will heat the air beforeit reaches the two hub motors 104. These two hub motors 104 (motorsattached to the wheels 114) are powered by the heated compressed air.Therefore, there are very few harmful emissions emitted directly fromthis vehicle 100.

The car 100 may not emit many harmful substances but it still has to berefueled; this is done is using an air-compressor 314. There are twoapproaches to filling the pneumatic vehicle 100. In the first method,the user will be able to fill the pneumatic vehicle 100 at a fillingstation much like a petrol station except there will be a largecompressor that will be able to fill the 65 liter air tank 106 in aminute. An efficient air compressor still uses energy to compress thegas and thus still makes a small impact on the environment but theseemissions are significantly less than a standard petrol or dieselvehicle in two ways, firstly in the emissions from the pneumatic vehicle100 directly (CO₂, NO₂, etc) and secondly the emissions and energyrequirements made in the refining of the fuel do not exist as air doesnot have to be refined or purified before it goes into the tank 106.There are, obviously, no “secondary” emissions.

The second approach to refueling the pneumatic vehicle 100 is to refuelat home as illustrated in FIG. 85. The home compressors will not be asbig as the petrol station one and therefore will take longer to refuel(4-6 hrs). Some ideas have been put forward for future infrastructure toaccommodate this vehicle 100. For example solar panels 316 could beinstalled on modern houses to offset the power requirements of thecompressor 314 and the large quantities of heat generated by thecompressors 314 will be used in a hot water heating system 318 to helpheat the water for a house 320 thus making the overall efficiency andenergy use less (see diagram below).

Other things that influence the environment during this stage are themaintenance and servicing of the pneumatic vehicle 100. As with allvehicles, the pneumatic vehicle 100 may require maintenance and repairto keep the pneumatic vehicle 100 operating smoothly and efficientlyover its lifespan. Maintenance will involve the use of new spare partswhich will have the same effects on the environment as making the partfor the car 100 originally. Second hand or recycled parts are also ableto be used in maintenance, these parts are better for the environment asthey are not being remanufactured.

Disposal of oils (Das 2001) is often one of the biggest environmentalproblems in this stage. If oils are not disposed of properly they cancontaminate soil and water. The pneumatic vehicle 100 reduces thisproblem significantly as it does not have as many types of oil or largequantities of oil. The only oils used in the pneumatic vehicle 100 maybe a hydraulic brake fluid and a few other minor lubricants as opposedto the liters of oil often found in gear boxes and engine blocks ofregular cars. This difference will make a large contribution to anenvironmentally safe pneumatic vehicle 100.

End-of-Life Vehicles (ELV)

The end-of-life vehicle or waste management stage considers what happensto the vehicle after is has served its useful life (once the car is moreexpensive to repair than it is worth). This stage is importantenvironmentally because it decides what parts of the car can be reused,recycled and disposed of in landfills or incinerators.

According to Das (2001) 24% of current vehicles end up in a landfillsite.

When a vehicle has been written off it is taken to an auto disassembler;this is where the car is stripped of all its reusable parts. These partsare often refurbished and sold on the second hand parts market.According to Das (2001) “ . . . this implies that for a disassemblyactivity to be profitable, the labor time, equipment needs, energyneeds, skill needs, and space requirements must be relatively small.”For this to happen Das (2001) suggests that when a car is designed itshould be designed for disassembly; that is, designed to be pulled aparteasily. If the car can be taken apart easily more people are likely towant to recycle the car and thus the recyclability of the car will goup.

Currently in the recycling of cars, the car is taken to an autodisassembler and all the parts that can be salvaged are removed. Onceall the useful parts have been removed the car is crushed and sent to ashredder where it is shredded and separated into 3 different categories:ferrous materials, non-ferrous materials and fluff (rubber, glass andother materials that are difficult to separate).

The ferrous materials are separated using a magnet and sent to a steelrecycling center where it is melted down with more original steel andre-used. Das (2001) implies that 25% of a new car is made from recycledsteel.

The non-ferrous materials which are often aluminum, copper and nickelare sent to their relative recycling plants.

The fluff is usually disposed of in land fill sites because itscomposition changes from hour to hour.

One of the biggest advantages the pneumatic vehicle 100 has is its easeof disassembly. The hub motors 104 can be removed more easily than in aconventional combustion engine as they are connected to the wheels 114and are easy to get to. In a conventional vehicle, the engine block ismuch larger and heavier and often needs special hoists to remove it aswell as a special place to remove the engine to, so that the oils fromthe engine block do not contaminate the soil. The hub motors 104 will beable to be refurbished or used again.

The fuel tank 106 and air hoses 296 are easy to remove from the bottomof the pneumatic vehicle 100 and most of these parts can be refurbishedand reused. Any parts that cannot be reused will have to go to a landfill site; this is because of the difficulty in recycling carbon fiber116 (air cylinder 106) and rubber (air hoses). These materials are usedbecause the weight and safety of a regular aluminum/steel cylinder arenot adequate to keep the pneumatic vehicle 100 efficient on thecompressed air.

The electric cables and electronic components can be pulled out of thedash board and reused or recycled depending on what they are. Forexample the copper in wires are often recycled and some batteries can berecycled or reused. The seats and can be pulled out of the pneumaticvehicle 100 easily and the air bladders 262 used in the seats 254 can berecycled along with the foam in the seats 254. The fabric 250 can beincinerated or placed in a land fill site.

The upper part 198 of the car 100 can then be separated from the lower200 by using heat to remove the adhesive. Once the adhesive reaches acertain temperature, the upper and lower vehicle 198, 200 can beseparated. The upper vehicle 198 can then be sent to the shredder andused for concrete filler. The lower vehicle 200 can have the last piecesof the interior and all suspension and steering components removed andreused/recycled. The rest of the lower vehicle 200 will be sent to theshredder so that the steel can be recycled.

The fluff in this pneumatic vehicle 100 will be reduced as the upperpart 198 of the vehicle 100 can be separated easily from the lower part200 by heating the adhesive that bonds the two surfaces. This will meanthat the lower part 200 that will primarily be steel that can be sentoff to the crusher and shredder; while the upper part 198 can beshredded and sent to a place to be used as filler in concrete or asphaltas it will be a homogenous materials of fiber glass.

Inventory Analysis Summary

FIG. 86 gives an estimate of the wastes produced by various rawmaterials from cradle to grave.

FIG. 87 indicates the environmental hazards that a generic vehicle willcontribute to the environment over its life. As can be seen in thetable, the most wastes that the car 100 contributes to the environmentare in the fuel use column with carbons, sulphurs and nitrogenscontributing the most. As the pneumatic vehicle 100 is powered bycompressed air theses emissions will be significantly reduced. It willnot reach zero as the compressor that is used to refuel the car 100requires energy which in turn will emit some harmful substances.

As the car 100 is a lot smaller we should also see a small decreaseacross the board; lowering all the air, water and soil pollutants.

Impact Analysis

According to the ISO 14044 standard, impact analysis is the phase oflife cycle analysis aimed at understanding and evaluating the magnitudeand significance of the potential environmental impacts for a productsystem throughout the life of the product. That is to take the emissionsthat the vehicle will produce over its life and define what harm it cando to the environment. FIG. 88 gives all the relevant information on theemissions; this table was adapted from FIG. 87.

There are 4 mediums of pollution in this life cycle analysis (LCA) theyare:

-   -   Air—Emissions released into the air;    -   Water—Emissions released into the water;    -   Soil—Soil contaminated by pollutants;    -   Energy—Energy requirements.

The 6 types of pollution are further categorized to a specific type ofpollution, the 6 types are:

-   -   Global Warming—Pollution that contribute to global warming;    -   Acidification—Pollutants that contribute to acidification of        air, water and soil;    -   Nitrification—Pollutants that cause nitrification in the        environment;    -   Eco-toxicity—Pollutants that cause toxic effects on ecosystems;    -   Human Toxicity—Cause toxic effect on humans;    -   Resource Depletion—The effect on non-renewable resources.

The pneumatic vehicle 100 will have similar effects on the environmentas a regular car 100 but in much smaller proportions. For instance theextracting and manufacturing stages will use far less materials as thecar 100 is far smaller and lighter than current vehicles. The use stagewill be significantly less, with almost negligible CO2, NO2, etc beingemitted directly from the car 100; this means that this stage will besignificantly less than a conventional car 100 operating today. Thepneumatic vehicle 100 has also been designed for disassembly andrecyclability with most of the car 100 being able to be recycled easilyand effectively. Thus, the overall effect on the environment and carbonfootprint of this car 100 will be significantly less than that of acurrent vehicle.

The pneumatic vehicle 100 has a maximum weight of 550 kg so it uses farless materials than a current small car; this means that every unit ofthe pneumatic vehicle 100 will have a smaller impact on the environmentthan most other vehicles.

According to the Australian government the use stage is the most harmfulstage to the environment as this is where the most emissions come from,currently these include carbon, nitrogen and sulphur emissions (whenburning fossil fuels). As the pneumatic vehicle 100 only has a small gasheater 110 to heat the compressed air before it reaches the hub motors104, the amount of emissions is a fraction of a normal car. This shouldreduce the emission contributed by the car 100 by a large amount. Torefuel this vehicle 100 an air compressor is utilized. The aircompressor 314 will require some energy to refuel the car 100 howeverthis is small compared to the amount of energy required to refine petrolfrom crude oil. The heat generated by the air compressor 314 at home canalso be used to help warm water in a boiler 318. Thus the impact on theenvironment in the use stage is far less than the average car producesnow.

Another relevant stage for the pneumatic vehicle 100 is the wastemanagement stage. This stage is becoming increasingly more important aswhat we do with the cars 100 when their useful life is over also effectsthe environment. An important thing to consider when designing a car 100today is to design it for disassembly. This means that the car 100should be designed to be taken apart easily at a recycler so that theycan easily remove parts to be refurbished and resold on the second handmarket as well as easily remove the parts that are to be recycled. If acar 100 can be taken apart easily there is more incentive for thedisassembler to recycle the car 100 as they are not spending largeamounts of money in labor and time to process the car 100 for recycling.The pneumatic vehicle 100 has been designed so that it can be recycledmore easily than a modern day car and it uses materials that cannot berecycled only where absolutely necessary, for example the carbon fiberfilament winding 116 that is utilized for safety and strength on the aircylinder 106. By increasing the recyclability of the car 100, less willend up in a landfill and the eco-toxicity and human toxicity will bereduced.

In conclusion, the pneumatic vehicle 100 will have a far smaller impacton the environment than a conventional car today has in all aspects.This reduction in impact ranges from the amount of materials required toconstruct the car 100 (thus lower energy requirements required to makethe car 100), all the way down to its high recyclability. See FIG. 88.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, and it isunderstood that various changes may be made without departing from thespirit and scope of the invention.

1. A pneumatic-powered automotive vehicle comprising: an elongate tank for storing compressed air; a chassis assembled with the tank such that the tank is oriented longitudinally and centrally in the chassis and provides a load-bearing structural member in the chassis; a plurality of wheels connected to the chassis; and a powertrain in fluid communication with the tank for being driven by the compressed air, and operably connected to one of the wheels.
 2. (canceled)
 3. The vehicle of claim 1 wherein the air tank further comprises: a generally cylindrical aluminum tank; a layer of carbon filament reinforced plastic provided over the aluminum tank for strengthening the aluminum tank; and a layer of fiberglass and aramid-fiber provided over the carbon filament reinforced plastic layer for protecting an external surface of the carbon filament reinforced plastic layer.
 4. The vehicle of claim 1 wherein the chassis further comprises: a first series of side support members connected to the air tank and extending laterally outboard from a first lateral side of the air tank; a second series of side support members connected to the air tank and extending laterally outboard from a second lateral side of the air tank opposite of the first lateral side; a first side panel connected to the first series of side support members at a lateral end thereof; and a second side panel connected to the second series of side support members at a lateral end thereof.
 5. The vehicle of claim 4 wherein the air tank is generally cylindrical; and wherein the chassis further comprises a series of mounting rings each affixed about the air tank for connecting one of the first series of side support members and one of the second series of side support members to the air tank.
 6. The vehicle of claim 5 wherein each of the mounting rings is insert molded into an exterior layer of the air tank.
 7. The vehicle of claim 4 wherein the chassis further comprises a rear bulkhead connected to a rear end of the first and second side panels for providing access for refilling the air tank.
 8. The vehicle of claim 4 further comprising a pair of side pillars each connected to one of the side panels for supporting a roof of the vehicle.
 9. The vehicle of claim 4 further comprising: a pair of rear rails each connected to a rear end of one of the side panels, each of the rear rails being inclined rearward of the side panels and functioning as structural members of the chassis; a suspension mount connected to the pair of rear rails at an orientation rearward and inclined relative to the side panels; and a suspension assembly connected to the suspension mount; wherein the plurality of wheels further comprises at least one wheel connected to the suspension assembly.
 10. The vehicle of claim 4 wherein the chassis further comprises a firewall mounted to a front end of each of the side panels.
 11. The vehicle of claim 10 wherein the chassis further comprises a pair of front support members each connected to the air tank and extending forward and outboard from the tank and connected to the firewall.
 12. The vehicle of claim 10 wherein the chassis further comprises: a pair of spaced apart crash tubes each connected to the firewall and extending forward of the firewall; and a bumper reinforcement member mounted to distal ends of the crash tubes.
 13. The vehicle of claim 12 wherein the pair of crash tubes are each formed from carbon fiber reinforced plastic.
 14. The vehicle of claim 1 further comprising: a suspension assembly mounted to a front of the chassis; and a pair of air motor hubs mounted to the suspension assembly, each air motor hub being in fluid communication with the air tank for being driven thereby; wherein the plurality of wheels further comprises a pair of wheels each mounted to one of the air motor hubs and driven thereby.
 15. The vehicle of claim 14 wherein the suspension assembly is further defined as a double wishbone suspension comprising: a pair of upper wishbones each pivotally connected to the chassis and one of the hubs; a pair of lower wishbones each pivotally connected to the chassis and one of the hubs; and a pair of coilover dampers each pivotally connected to the chassis and one of the lower wishbones.
 16. The vehicle of claim 15 wherein the chassis further comprises: a pair of elongate side panels; a firewall mounted to a front end of each of the side panels; a pair of spaced apart crash tubes each connected to the firewall and extending forward of the firewall; a bumper reinforcement member mounted to distal ends of the crash tubes; and a pair of mounts each affixed to one of the crash tubes for providing the pivotal connection of the corresponding upper wishbone and coilover damper with the chassis.
 17. The vehicle of claim 16 wherein the suspension assembly further comprises a carbon fiber strut brace connected to each of the pair of mounts.
 18. The vehicle of claim 16 wherein the chassis further comprises a glass fiber reinforced thermoset plastic subframe mounted to the firewall beneath the pair of crash tubes and extending forward of the firewall, the subframe providing the pivotal connection of the lower wishbones with the chassis.
 19. The vehicle of claim 14 further comprising: a pair of disk rotors, each mounted to and driven by one of the air motor hubs; a master cylinder supported on the chassis; an electronically controlled linear actuator operably connected to the master cylinder for applying pressure on the master cylinder; and a pair of single hydraulic floating piston calipers each attached to a housing of one of the air motors, for engaging one of the pair of disk rotors, each caliper being driven by the master cylinder for braking the corresponding disk rotor.
 20. The vehicle of claim 14 further comprising: a pair of rear rails each connected to a rear end of one of the side panels, each of the rear rails being inclined rearward of the side panels and functioning as structural members of the chassis; a suspension mount connected to the pair of rear rails at an orientation rearward and inclined relative to the side panels; and a suspension assembly pivotally connected to the suspension mount about an axis that extends downward and rearward; wherein the plurality of wheels further comprises a rear wheel connected to the suspension assembly for trailering behind the front driven wheels.
 21. The vehicle of claim 20 further comprising a rotary steering damper interconnecting the suspension assembly to the suspension mount for stabilizing the rear wheel.
 22. The vehicle of claim 20 wherein the suspension assembly further comprises a pair of upside down telescopic fork shock absorbers.
 23. The vehicle of claim 20 further comprising a regenerative braking rear hub mounted on the suspension assembly and supporting the wheel for braking the rear wheel and generating electricity from the braking of the rear wheel.
 24. A chassis for a pneumatic-powered automotive vehicle comprising: an elongate tank for storing compressed air; a first series of side support members connected to the air tank and extending laterally outboard from a first lateral side of the air tank; a second series of side support members connected to the air tank and extending laterally outboard from a second lateral side of the air tank opposite of the first lateral side; a first side panel connected to the first series of side support members at a lateral end thereof; a second side panel connected to the second series of side support members at a lateral end thereof; a plurality of wheels connected to the side panels; and a powertrain in fluid communication with the tank for being driven by the compressed air, and operably connected to at least one of the wheels for driving the vehicle. 